Waffle Moulds

Waffle Moulds

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.

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 two-way spanning, cast in-situ, reinforced, ribbed concrete floors.

Design

Waffle Moulds

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:

  • 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

Waffle Moulds

Typically, Cordek waffle 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 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.

Manufacture

Waffle Moulds

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.

Environmental facts about Filcor EPS

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

* Global warming potential (GWP) is a means of measuring the strength of different 'greenhouse' gases in the atmosphere and can be used to define the impact greenhouse gases have on global warming over specified periods of time. As an example CO has a GWP of 1 over 100 years. All other greenhouse gases HFC, CFC HCFC and methane are measured relative to CO2.
Filcor Recycling
Filcor is 100% recyclable. As a single polymer, Filcor is straightforward to recycle and is recyled into items such as replacement hardwood decking or garden furniture and coat hangers

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

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Case Study

Farringdon Station Eastern Ticket Hall

Cordek was challenged with finding a solution to create the recessed voided ceiling which is a key feature of the Eastern Ticket Hall.