Floors

Floor panels or wide floor slabs: these are the ideal substrate for loadbearing concrete floors.

At Kerkstoel 2000+ we make floor panels entirely to measure. For any space and in any shape. We create the requisite recesses at the start during the production process. We also install the required built-in parts in advance and modify the under-reinforcement.

Kerkstoel 2000+ wide floor slabs carry the BENOR and KOMO inspection marks. So you can be sure that you are installing top-quality floor panels.

What are wide slabs?

Wide slabs are used as the constructive and aesthetic underside of a concrete floor. They are the ideal substrate for loadbearing concrete floors and can be manufactured in all shapes, up to 7 cm thickness. These wide slabs are available in various widths: 1m20, 2m40, 3m and room-wide.

Our wide slabs are provided with under-reinforcement, with a flat and smooth surface on the underside. After placing the wide slabs the pipework is laid and the upper reinforcement applied. Finally, concrete is poured onto the plates up to the desired floor thickness.

The result is a solid concrete floor where the load is perfectly distributed.

Kerkstoel wide slabs are reinforced concrete wide slabs that comply with:

the PTV 202 Probeton BENOR regulations for Belgium
NBW_EN_13369
NBW_EN_13147
the KOMO specifications
the certificate with product certificate number K2188/95 and the ISO 9001 standards

Benefits

Form

Because we make wide slabs to measure, you save time on site and use less materials. As regards the shape, we follow the contours of the design when manufacturing wide slabs, for whatever kind of space.

Reinforcement

The full bottom reinforcement is incorporated into the wide slabs when we deliver them. You therefore only have to assemble them. Beams can be created in the floor and it is possible to make openings.

Integrated parts

All the integrated parts are mounted in advance in the correct location. Provisions for electrical, sanitary, air-conditioning and heating services can be built in without any problems.

Durability

Kerkstoel wide slabs are produced in a professional manner and comply with the most stringent standards:

optimum resistance against environmental influences
optimum fire resistance

Finishing

The large surface area of the wide slabs means there are few joints. The smooth frame surface also provides an ideal substrate for spray plastering. The end result is a solid monolithic floor that ensures good noise insulation and the perfect distribution of the floor load. wide slabs are the solution for a rapid, simple and robust construction.

Weight

Kerkstoel wide slabs weigh less than the standard wide slabs available on the market. This has its advantages: not only do you require less transportation, you can also use a crane with a lower lifting capacity on your site than with standard wide slabs. It goes without saying that this also has financial advantages.

Production process

Drawing the layplan

The layplan will first be created in consultation with the contractor. As soon as the contractor and the consultancy bureau have approved the layplan, the production process can start.

Formwork with robot

Wide slabs are shuttered on movable metal tables. The central computer sends all the necessary information to the formwork robot. This robot applies the transverse and longitudinal settings and also makes the openings.

Reinforcement

Creating the reinforcement
The reinforcement is specially custom made for every floor panel. The client has a choice of various diameters of high-quality reinforcement rods.
Reinforcement in the formwork
The reinforcement is placed fully automatically in the formwork and offers an optimum concrete top layer depending on the required fire resistance

Concreting

When concreting we take account of the thickness of the wide slab. When pouring we constantly weigh the quantity of concrete to guarantee the correct thickness. The computer control of the concreting machinery ensures that the concrete is distributed extremely precisely over the entire surface.

Storage in dry room

We store the newly concreted floor panels on steel tables which are heated constantly at the right temperature with the precise humidity level, taking into account the desired concrete strength.

Stripping

After 8 hours in the drying chamber, the precast element will be hard enough to be dismantled and transported.

Delivery& fitting

Are Kerkstoel wide floor slabs going to be delivered soon to your site? We will tell you stage by stage the best way to deal with the delivery and fitting. Be sure also to read our assembly manual for floor panels for more information.

DELIVERY & FITTING - STEP 1

Unloading

Our wide slabs are delivered on trucks with a length up to 18 m and a clearance height of at least 4 m. If you are expecting a delivery, make sure that the crane and the low loaders can access the site without difficulties. Take account of any street obstructions, sharp corners, parked cars, etc.

The wide slabs are unloaded from the lorry using the site crane, and they are usually placed directly in their intended locations according to the placement plan. Hook the carabiner hooks in the diagonals and never on the top concrete reinforcing bar. The standard weight of the wide floor slabs is approximately 125 kg/m2 at a thickness of 5 cm.

If the wide slabs are temporarily stored on the construction site, then store them on a flat and sufficiently strong substrate. Put the panels on 2 square timbers that are as long as the panel, so the flat underside is not damaged. The square timbers are best laid at 1/5 panel width from the edge. It is necessary to use 3 or 4 square timbers for panels exceeding 4.5 m. It is possible to stack a maximum 10 panels on top of each other.

DELIVERY & FITTING - STEP 2

Falsework

Before you fit the wide floor slabs install the falsework. The distances between the mounting props are stated in the layplan. Always place the yoke beams transverse to the lattice girders. The 50 mm bearing area counts as support. A bed of mortar is recommended!

Fitting

Preferably lay the wide slabs straight from the truck in the correct position. All wide floor slabs are numbered in the installation drawings. Lower the slab completely horizontally onto the bearing surface and install the floor slabs with precamber.

Openings

Potential openings in the floor are often provided for during the production of the wide slabs . The openings and edges will be shuttered up to the level of the finished floor on the site. If the openings for the supply of electrical power were not made during production, they can be drilled longitudinally along the bottom after placement. Caution: if drilling takes place from the top, parts of the smooth underside will break off!

DELIVERY & FITTING - STEP 3

Strengthening the joints

Strips of reinforcement mesh or individual rods are placed over the joints between the floor panels as joint reinforcement. The specifications for this reinforcement are given in the layplan.

Cleaning the panel surface

If the upper face of the wide slab has become soiled, clean it in order to ensure good adhesion between the wide slab and the freshly poured concrete. The surface must be made dust-free and moistened before pouring the concrete.

Pouring the concrete

The concrete must be poured and sealed according to the required quality and consistency in one single operation. The reinforcement must not shift or sink during this operation.

Removal of the props

Only remove the props when the concrete has sufficiently hardened. It is necessary to comply with the provisions of the NBN B15-001 and NBW_EN_206_1:2001 standards in this respect.

Specification guidelines

The works comprise:

preparation of the bearing surfaces,
delivery and fitting of:
- the props and any necessary formwork
- the floor panels as described below
- the additional reinforcement
- the compression slab
- making the necessary provisions for openings
- removing temporary equipment
- if need be cleaning the visible surfaces and finishing the edges.

Lastenboek breedplaat.pdf

Contact us

Ready to take the first step towards a customized prefab solution? Or do you have specific questions for us? Feel free to contact us.

Other floors

Wide slabs with weight-saving components

ACTIV floors