Waffle Moulds are a reusable formwork system for constructing two-way spanning ribbed concrete floors, which can achieve greater spans and use less concrete when compared to traditional flat slabs.
Traditionally manufactured from Filcor EPS with an external skin, each waffle mould is made to suit the individual requirements of the project and can be re-used multiple times. When struck, the waffle 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 two-way spanning, cast in-situ, reinforced, ribbed concrete floors.
When developing a waffle 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 waffle moulds are manufactured from one of the following material types:
One of the factors determining the most appropriate material used to manufacture a waffle 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 waffle 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 waffle mould, it may comprise of a number of individual units that require assembly on site.
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