Constructing cast in-situ concrete helical and spiral staircases can prove challenging without the use of the appropriate formwork. Bespoke formers can allow the complex geometry of the staircase to be created, whilst also achieving a soffit finish of sufficient quality to be left exposed.
Each former is designed to meet the specific requirements of the project, including the size, shape, finish and number of re-uses required. Based upon this information our designers will select the most appropriate material for each former and create a 3D CAD model for approval before commencing manufacture.
*Please refer to National Structural Concrete Specification (NSCS) Edition 4 guidance available below.
Used for the construction of cast in-situ reinforced concrete helical and spiral staircase soffits with either complex or non-standard geometries, profiles and sizes.
When developing a helical or spiral staircase former 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 staircase soffit formers are manufactured from one of the following material types:
One of the factors determining the most appropriate material used to manufacture a staircase soffit former 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 into CAM data allowing accurate manufacture of the staircase soffit former 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 former, it may comprise of a number of individual units that require assembly on site. This can prove advantageous in certain applications, such as those with limited access space or where positioning on supporting falsework is required.
In cases such as these, design features and installation guidance can be provided to minimise grout loss at joint locations and improve the concrete finish achieved.
The manufacture of Filcor is a low pollution process. Steam is he key component and the water is re-used many times. There is no waste in the process as all cut offs or rejects are recycled.
Filcor is 98% air. This makes Filcor a uniquely resource-efficient material with small carbon footprint.
Filcor is HFC, CFC and HCFC free and Pentane is used as its blowing agent. Pentane has a low Global Warming Potential* (GWP) of less than five. (The EU does not register pentane as a substance hazardous to human health or environment.)
Styrene, used in the manufacture of Filcor, occurs naturally in many commonplace items including strawberries, beans, nuts, beer, wine, coffee beans and cinnamon