For applications where a traditional trough or waffle mould cannot meet the complexities of the design brief, a bespoke feature mould solution should be considered. These formwork systems are capable of achieving complex rib configurations in addition to retaining the features normally associated with ribbed slab arrangements.
Manufactured from a wide range of material options, each feature mould is made to suit the individual requirements of the project and can be re-used multiple times. When struck, the mould, subject to specification, can achieve a good quality finish for exposed applications.
Each mould is designed to meet the specific requirements of the project including the size, shape, finish and number of re-uses. Using this information, our designers will select the most appropriate material for each former and create a 3D CAD model for approval, which when accepted will allow CNC machining of the finished formwork solution.
*Please refer to National Structural Concrete Specification (NSCS) Edition 4 guidance available below.
Used for the construction of cast in-situ, reinforced, ribbed concrete floors with a complex rib arrangement.
When developing a feature mould design, the following factors should be considered in addition to reviewing any CAD drawings, 3D models, specifications etc that are available:
Once the project requirements have been confirmed, a conceptual design can be completed along with provision of a quotation confirming proposed material type, features, quantities, manufacturing lead time and costs.
Typically, Cordek feature moulds are manufactured from one of the following material types:
One of the factors determining the most appropriate material used to manufacture a feature mould is the required concrete finish.
Further information in relation to the classification of concrete finishes can be found within the National Structural Concrete Specification (NSCS) Edition 4 guidance, a copy of which can be downloaded from the Certification, Guidance and Approval section below.
Once approved, the agreed 3D CAD Model will be converted in to CAM data allowing accurate manufacture of the feature mould via CNC hot wire cutting and / or 5-axis routing dependant on factors such as material type, complexity of shape / profile and required tolerances.
In some instances, due to the required dimensions of the feature mould, it may comprise of a number of individual units that require assembly on site.