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A voided biaxial slab can remove concrete from the low-stress central zone of a two-way floor while retaining the reinforcement and concrete needed for structural action. In the project covered here, ProHealth Care’s 76,140-square-foot D.N. Greenwald Center in Mukwonago, Wisconsin, used BubbleDeck void formers; Building Design + Construction reported a 30% reduction in non-axial dead load and 786 cubic feet of concrete saved.
Those numbers describe one 2016 case study, not a guaranteed result for every building. The slab still requires project-specific engineering for stiffness, shear, openings, local code compliance, construction sequencing and support conditions.
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Outbyte PC Repair FREEClear out junk files and repair common Windows errorsFree Scan →Outbyte Driver Updater FREEScan for outdated or missing drivers - takes under a minuteDriver Scan →What is a voided biaxial slab?
A voided biaxial slab is a reinforced-concrete floor designed to span in two directions, with hollow formers placed in the slab’s central region. The central zone is close to the slab’s neutral axis, where concrete contributes less to bending resistance than the concrete near the top and bottom faces. Replacing selected central concrete with hollow plastic formers reduces self-weight while leaving a two-way reinforced-concrete system around the voids.
BubbleDeck describes its system as recycled-plastic void formers held in reinforcement modules and embedded in a cast-in-place slab. The manufacturer’s product overview distinguishes this from a conventional solid slab: the voids are distributed through the panel rather than concentrated in a single service trench or beam pocket. The result is still a concrete slab, not a lightweight finish or a suspended ceiling system.
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“Biaxial” refers to load transfer in two perpendicular directions. That matters in square or nearly square floor panels supported by columns, walls or beams on more than one side. A project engineer must still determine whether the proposed geometry, span-to-depth ratio, support layout and loading justify two-way action; the presence of void formers does not automatically make any floor a biaxial slab.
What did the D.N. Greenwald Center case study report?
The project was ProHealth Care’s D.N. Greenwald Center in Mukwonago, Wisconsin. Building Design + Construction’s January 20, 2016 case study describes a 76,140-square-foot facility with a medical walk-in clinic, emergency services, an ambulance garage and expanded imaging services.
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| Project fact | Reported information |
|---|---|
| Facility | ProHealth Care D.N. Greenwald Center |
| Location | Mukwonago, Wisconsin |
| Area | 76,140 square feet |
| Slab system | BubbleDeck voided biaxial reinforced-concrete slab |
| Reported non-axial dead-load reduction | 30% |
| Reported concrete saving | 786 cubic feet |
| Reported fabrication-drawing schedule saving | Eight weeks |
| Case-study source | Building Design + Construction, 2016 |
The article says the recycled-plastic void formers displaced concrete along the slab neutral axis. It attributes the 30% reduction in non-axial dead load and the 786-cubic-foot concrete saving to this project. The article does not disclose the baseline slab quantity, the calculation method, or independent verification of those figures, so they should be read as reported project results rather than a performance guarantee.
The named project team included Eppstein Uhen Architects, Pearson Engineering for mechanical, electrical and plumbing work, Mortenson as construction manager and GRAEF for fabrication drawings. The case study says GRAEF’s drawings saved eight weeks; that is a project-specific schedule statement, not a standard duration for every BubbleDeck job.
How is a BubbleDeck slab assembled?
The exact sequence depends on whether the project uses cast-in-situ reinforcement modules or a precast half-slab. In both versions, the voids must be located accurately, restrained during the pour and coordinated with reinforcement, supports, penetrations and temporary works.
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- Set the formwork or precast base. For a cast-in-situ solution, crews place traditional horizontal formwork. The manufacturer’s precast half-slab option uses a precast concrete bottom layer that replaces the horizontal portion of the formwork.
- Position the reinforcement modules and void formers. BubbleDeck’s Type B installation manual describes reinforcement modules containing the plastic void formers. Their spacing, cover, edge conditions and support-zone details follow the project drawings.
- Install remaining reinforcement. Bottom and top reinforcement, punching-shear reinforcement, perimeter bars, column strips and local solid zones are completed as required by the engineer.
- Check services and openings before concrete. Medical buildings often have dense mechanical and electrical coordination. Penetrations that were not designed into the slab can conflict with voids or reinforcement and may require a revised detail.
- Place and consolidate concrete. The modules are encased in concrete on site. Pour planning, vibration, cover checks and protection of the void formers are construction-control issues, not optional finishing steps.
- Cure, strip and inspect. Formwork removal, curing and inspection follow the project specification. A precast half-slab can reduce horizontal formwork, but it introduces lifting, delivery, bearing and temporary-propping requirements that must be planned.
The manufacturer’s implementation guidance presents the system as conventional reinforced-concrete design with system-specific adjustments. That means the formers are not a substitute for structural drawings, a pour plan or a temporary-works design.
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How much concrete and weight did the project save?
For the D.N. Greenwald Center, the published figures are 786 cubic feet of concrete saved and a 30% reduction in non-axial dead load. Building Design + Construction linked the reduction to removing concrete from the slab’s central region while maintaining biaxial strength.
Neither figure can be converted into a universal percentage for another project without a new design. Results depend on panel dimensions, slab thickness, column spacing, design loads, support conditions, edge zones, openings, required fire and acoustic performance, and how much of the floor must remain solid for shear or services. A building with many irregular penetrations or heavy concentrated loads may have less voided area than a regular grid.
The case study does not publish the original concrete volume, so the 786-cubic-foot saving cannot be independently reconstructed from the article alone. It also does not provide a life-cycle assessment, embodied-carbon calculation or independent verification that every environmental claim was achieved on the building. Reduced concrete volume can be a useful project objective, but environmental conclusions require a defined baseline and a full assessment of reinforcement, plastics, transport, lifting, formwork and end-of-life treatment.
Does reducing dead load change the structural design?
Yes. Removing concrete changes more than the truck quantity. The engineer must account for the lower permanent load, altered stiffness and reduced shear capacity in voided portions. BubbleDeck’s implementation guidance says designs generally begin with conventional solid-slab methods under applicable local standards, then apply system-specific adjustments.
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Shear is especially important near columns, walls and other supports. The manufacturer indicates that high-shear regions may remain solid or receive additional shear reinforcement. A void that is acceptable in the middle of a span may be inappropriate beside a column because punching shear and load-transfer demands are concentrated there.
Lower self-weight can affect several downstream decisions:
- Support reactions: Columns, walls, foundations and piles may see lower permanent reactions, but the revised load path must be calculated rather than assumed.
- Deflection and vibration: Lower mass does not automatically mean lower deflection. The engineer must use the system’s adjusted stiffness and check serviceability under the governing code.
- Shear and punching: Voided zones have less concrete available for shear resistance, so solid bands, thicker regions or added reinforcement may be required.
- Fire, acoustics and durability: Cover, fire rating, impact, sound transmission and exposure requirements remain project requirements. The available data does not establish a universal fire or acoustic rating for every configuration.
- Openings: A later penetration can cut reinforcement or intersect a former. The manufacturer’s FAQ says post-construction openings require confirmation from the BubbleDeck Group; the project engineer must approve any alteration.
What should the design team verify before specifying a voided slab?
Owners should ask for a documented engineering basis before treating the system as a value-engineering option. A practical review includes:
- Define the structural grid and loads. Provide spans, column sizes, wall lines, live loads, equipment loads, partitions, façade reactions and any vehicle or impact loads.
- Map solid and voided zones. Identify column strips, wall supports, transfer areas, balconies, edges, cantilevers, penetrations and locations where high shear requires solid concrete.
- Confirm the code path. The engineer should identify the current local structural and fire standards, material design strengths, load combinations and any approval or peer-review requirements.
- Check serviceability. Review deflection, vibration, crack control and long-term effects using the adjusted stiffness rather than assuming solid-slab behavior.
- Coordinate services early. Freeze major penetrations, sleeves, drains, medical-gas routes and equipment anchors before reinforcement modules are fabricated.
- Design temporary works. Account for delivery, lifting, propping, pour sequence, construction loads and the capacity of formwork or precast bearings.
- Plan quality control. Specify checks for module placement, cover, reinforcement continuity, concrete consolidation and records of any field changes.
- Set an alteration protocol. State who may approve drilling, coring, scanning or cutting after construction and require written confirmation before work begins.
BubbleDeck’s FAQ says the product requires professional-engineer endorsement. That manufacturer guidance reinforces a basic rule: the local project engineer, not a generic product diagram, controls the final design and code decision.
What are the construction trade-offs?
A voided slab can trade concrete volume for coordination and installation work. The cast-in-situ module approach retains familiar concrete placement but adds factory-made modules that must arrive in the correct sequence and stay accurately positioned. The precast half-slab can remove much of the horizontal formwork, yet it requires transport planning, crane capacity, bearing details and temporary stability.
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Regular floor plates are generally easier to module than heavily irregular plans. Dense openings, transfer structures, unusual edge geometry or concentrated loads can force more solid areas and reduce the potential saving. Site access also matters: a project may have enough lifting capacity for precast units but limited laydown space, or the reverse.
Cost should be evaluated as an installed system, not as a concrete-only comparison. The estimate should include void formers, reinforcement, fabrication drawings, engineering review, formwork or precast units, cranes, temporary propping, labor, concrete placement, inspection and any schedule effect. The supplied case study reports no installed price, so it cannot support a claim that BubbleDeck is cheaper than a solid slab on another project.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What does the eight-week schedule figure mean?
Building Design + Construction reported that GRAEF’s fabrication drawings saved eight weeks on the D.N. Greenwald Center project. The article does not define whether the comparison was against a particular baseline, nor does it establish that every project receives the same benefit.
For a new project, schedule analysis should separate design production from manufacturing, delivery, erection, reinforcement, concrete pours and curing. Early release of coordinated drawings may help a fixed construction sequence, but late architectural or MEP changes can erase that advantage. Treat the eight-week figure as evidence of what the named team reported, not as a promised lead-time reduction.
Can a voided biaxial slab replace a solid slab on any project?
No. It is an option that may fit some regular two-way floor systems after engineering review. The correct comparison is project-specific: span and loading, dead load, stiffness, shear behavior, formwork, temporary works, lifting, concrete and reinforcement quantities, schedule assumptions, code basis and installed cost.
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A solid slab may remain preferable where the plan has many penetrations, severe support shear, transfer forces, short spans, unusual vibration criteria or limited access for modules. Conversely, a voided system may deserve study where self-weight is a major design driver and the floor grid allows repeatable modules. The case study supports investigating the option; it does not identify a universal winner.
What can be concluded from this case study?
The D.N. Greenwald Center demonstrates a specific use of voided biaxial construction: recycled-plastic formers displaced concrete near the neutral axis, and the published project account reports 30% lower non-axial dead load and 786 cubic feet less concrete. Those are useful reference points for an early feasibility discussion.
They are not a generic slab calculator. The source does not publish the baseline quantity, calculation method or independent verification, and the manufacturer’s technical material is product guidance rather than independent test evidence. Any owner considering the system should request stamped calculations, local code documentation, fire and acoustic information where applicable, a temporary-works plan, coordinated opening details and a project-specific cost and schedule comparison before committing.
Frequently Asked Questions
Can contractors drill or core a BubbleDeck slab after construction?
Not without approval. BubbleDeck’s FAQ says post-construction openings need confirmation from the BubbleDeck Group, and the project engineer must check reinforcement, void locations, shear and the proposed opening detail before work starts.
Is the recycled-plastic void former itself a structural member?
No. The former creates an intentional void; the surrounding reinforced concrete and reinforcement provide the structural system. Its exact material, restraint and fire-related requirements must be accepted in the project design rather than inferred from the word “recycled.”
Is a 30% dead-load reduction normal for every voided slab?
No published evidence in this case establishes a typical percentage. The reported 30% applies to the D.N. Greenwald Center and will vary with slab depth, spans, support zones, openings, loads and the proportion of the panel that can safely be voided.
What information should be included in a tender for this system?
Include the structural grid, design loads, slab zones, void-module layout, concrete and reinforcement specifications, lifting or propping requirements, service penetrations, inspection hold points and the engineer’s alteration procedure. Requiring these items lets bidders price the complete installed system instead of comparing concrete volume alone.
