Trough Moulds

Trough Moulds

Trough Moulds are a reusable formwork system for constructing one-way spanning ribbed concrete floors, which can achieve greater spans and use less concrete when compared to traditional flat slabs.

Traditionally manufactured from Filcor with an external skin, each trough mould is made to suit the individual requirements of the project and can be re-used multiple times. When struck, the Trough 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.

Features

  • Manufactured to meet project specific requirements
  • Available in a wide range of materials
  • CNC machined for consistent, tolerance-controlled surfaces
  • Re-usable where moulds of the same size, shape and profile are required
  • Basic, Ordinary, Plain & Special Finishes achievable*

*Please refer to National Structural Concrete Specification (NSCS) Edition 4 guidance available below.

Applications

Used for the construction of one-way spanning, cast in-situ, reinforced, ribbed concrete floors.

Design

Trough Moulds

When developing a trough mould design, the following factors should be considered in addition to reviewing any CAD drawings, 3D models, specifications etc that are available:

  • Dimensions, geometry and features
  • Required concrete finish (Basic, Ordinary, Plain or Special)
  • Proposed number of uses – single or multiple
  • Loadings – specifically relating to the proposed concrete pour depths
  • External structural support method
  • Delivery method, unloading requirements and access restrictions
  • Positioning, installation and sequence of construction
  • Striking, removal and re-use or disposal

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.

Materials & Finishes

Trough Moulds

Typically, Cordek trough moulds are manufactured from one of the following material types:

  • Filcor Expanded Polystyrene (EPS) with Correx skin
  • Filcor EPS with ABS skin
  • Filcor EPS with Sheet Fibreglass skin
  • Filcor EPS with a spray applied Polyurea skin
  • Glass Reinforced Plastic (GRP)

One of the factors determining the most appropriate material used to manufacture a trough 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.

Manufacture

Trough Moulds

Once approved, the agreed 3D CAD Model will be converted in to CAM data allowing accurate manufacture of the trough 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 trough mould, it may comprise of a number of individual units that require assembly on site.

Downloads

Data Sheets

Product Issue Date Version Size Download
Filcor Data Sheet 03/2021 8 405.9 KB

Standard Details

Product Issue Date Version Size Download

MSDS Data Sheets

Product Issue Date Version Size Download
Expanded Polystyrene MSDS 06/2017 5 137.3 KB

Certification, Approval & Guidance

Product Issue Date Version Size Download
National Structural Concrete Specification (NSCS) Edition 4 1.2 MB

Brochures

Product Issue Date Version Size Download
Construction Solutions 01/2020 2 6.6 MB

NBS Clauses

Our NBS Clauses are hosted on the external website - view NBS Clauses

BIM Library

Please select the BIM file in the format you require.

Name IFC Size IFC Download Revit Size Revit Download
Sorry, no matching files

Not sure which product meets your requirements?

Contact a Technical Advisor now

Case Study

Royal College of Pathologists

Cordek were asked by the specialist concrete frame contractor Oliver Connell & Son to devise a formwork system to allow the construction of ribbed concrete floors.