TROUGH AND WAFFLE MOULDS

For In-situ Ribbed Floors

C O R D E K T RO U G H S YS T E M S W R M O U L D S

Trough and Waffle Moulds

Engineers and designers continue to find in-situ ribbed floors a cost effective, and if exposed, an aesthetically pleasing method of construction. These ribbed floors fall into two main categories-

One-way spanning TROUGHS

Or

Two-way spanning WAFFLES

Trough Moulds
The Cordek Trough System For nearly 30 years Cordek moulds have been used extensively in a wide variety of contracts throughout the UK. The density of the expanded polystyrene core, and the strength of the polypropylene liner used for a particular application, depends upon the number of re-uses and the quality of finish that are needed. Individual units are interlocked to form a trough. A typical configuration is:

End Unit

Standard Intermediate Unit

Striking Unit

Non-Standard Intermediate Unit

End Unit

620

1230

310 Combined Length 3680mm

900

620

The moulds are manufactured by bonding a polypropylene skin to a solid expanded polystyrene core.

As can be seen, each trough length is made up of a number of standard units, which are used in whatever multiples are needed, and one variable unit is added. In some instances a 615mm long intermediate unit is introduced to avoid using a variable intermediate mould of less than 250mm.

Bonded Correx Polypropylene Skin Solid Expanded Polystyrene Core

4mm thick Correx Flange

Trough Moulds
The Cordek system offers almost infinite variability in cross-section and length.
It means that the engineer is able to design the optimum troughed slab profile, to suit the span and floor loadings required.

Skewed, tapered or even curved moulds can all be readily supplied.

Elliptical and radii cross-sections

Moulds at 600, 900 and 1200mm centres are most frequently specified. A schedule is available which shows the concrete displaced by different depths, widths and rib centres. The figures for sizes not detailed are readily available from our Technical Services department. To calculate the volume displacement, the following formulae apply:
C

38 38

A D

Trough Volume per m2

B ((AxB) - (B x C) - 0.00144) D B ((A x B) - ( B x C) - 0.00144)

Trough Volume per m run =

In the illustration above, where: A = 0.750m C = 8* B = 0.375m D = 0.900m Trough Volume per m2 = 0.291/m3

* Minimum recommended side slope is 1: 8.14 (7)

Trough Volume per m run = 0.262/m3

A specially designed floor, requiring over 40 different mould sizes. Our Technical Department produced a detailed manufacturing schedule to suit this complex design.

10o

1150

1100

Back-up Support and Benefits

The Cordek trough mould system is tailored to suit the requirements of architects and engineers. It offers the following benefits:

Available on short lead times Very competitively priced Fully proven over nearly 30 years Easily modified on site to accommodate variations Can be re-cycled at Cordeks Slinfold plant The EPS core is a good insulant and accelerates the rate of concrete cure. Give a good industrial finish

Cordeks sales team is on hand to give any site assistance that is needed while the in-house technical department provides any information or prices that the designer requires.

The technical department also provides the successful contractor/subcontractor with detailed take-offs and schemes to optimise mould usage and minimise wastage.

The professional support given by everyone at Cordek has been essential to the success of the Cordek system, which is extensively used throughout the UK and in overseas markets.

A project in Bahrain

Trough System Application

The Cordek system is increasingly used on complete support systems and as can be seen, either the butting flanges are stapled to the deck, or the moulds are secured by means of a plywood strip which enhances the rib finish. The joints have to be taped and a suitable release agent applied. APPROVED ACCESSORIES ARE AVAILABLE FROM CORDEK.

Pouring Cordek moulds are extremely resistant to compression but surcharging with concrete, point loads and excessive sideways pressure, should all be avoided. Striking Remove the striking unit first and then remove the other units using a compressed airline.The detailed procedures for positioning, pouring and striking are available in a separate installation guide.

Warning: Prevent sparks from welding torches and angle grinders from coming into contact with the moulds.

Cordek moulds have been successfully used bolted to tables but this technique should not be employed without consulting our Technical Services dept.

Trough Moulds
Polypropylene
Polypropylene T Forms Four standard depths of troughs are available for HIRE at economic rates.The finish to the soffit of the slab is of a utility standard, and the trough section is often used to carry services above the suspended ceiling.

These T Forms can be hired from our subsidiary company WR Moulds (UK) Limited, who can be contacted on: 01777 708432.

Polypropylene T Forms
Characteristics

Trough D1 D2 D3 D4

Depth mm 175 250 325 400

Rib Width mm 125 125 125 125

Rib Centre mm 600 600 600 600

Unit A

Unit B

100

75mm R

15mm R

475mm 525mm 600mm

Waffle Moulds
Polypropylene
The WR System For two-way spanning ribbed floors, the WR range of injection formed polypropylene waffle moulds are the most frequently specified. They are easily struck by flexing

Only available on hire,WR Waffle Moulds are supplied in 7 standard sizes.

The following tables provide essential information to the specifier. Standard 8M waffle mould
800mm rib centres

Table 1

9M waffle Standard mould

900mm rib centres

Table 2

Depth mm 200 250 300 400

Weight Kg 5.00 5.40 5.75 7.25

Void Volume of mould m3 0.0765 0.0927 0.107 0.135

Void volume per m2 of floor m3 0.120 0.145 0.167 0.211

Depth mm 225 325 425

Weight Kg 9.30 11.40 13.40

Void Volume of mould m3 0.116 0.158 0.199

Void volume per m2 of floor m3 0.143 0.195 0.240

Waffle Mould
Dimensions

Table 3

Waffle Type 8M 9M

Rib Centre mm 800 900

Base Size mm 675 x 675 775 x 775

Rib Width mm 125 125

Each mould design is square in plan allowing them to nest for storage, and making them quick and easy to use.

Waffle Moulds
Polypropylene
These moulds now all have butting flanges which enhances the rib finish and enables them to be readily used on complete support systems.

They provide a good finish and have frequently been left exposed in car parks, hospitals, retail centres and hotels. As these photographs show however, they can also be painted to provide an enhanced finish.

Standard waffle moulds can be hired at very competitive rates from WR Moulds (UK) Limited, who can be contacted on: 01777 708432.

The Cordek waffle mould is again made by bonding a polypropylene sheet to an expanded polystyrene core.

These moulds are only used when non-standard sizes are required and when the uses are limited.

Cordek has the capacity to meet your requirements for all types of trough and waffle mould.

For more information please contact us on 01403 799600.

For our detailed literature on these other Cordek Solutions, please call our technical sales on: 01403 799601

Groundform
A formwork system for in-situ ground beams and pile caps

Cellform
Like Groundform, but with built-in protection against ground movement

Cellcore
For protecting foundations against ground movement

Claymaster
Low density polystyrene for accommodating horizontal ground movement

Ventform
For venting hazardous gases from under buildings

Correx & Seekure

For temporary protection applications

Cinema Floors
A formwork system for forming sloped and dished floors

Formwork & Voidformers

For piling, bridges, embankments

Specialist Formwork
Including archways, columns, staircases, refractory linings

Tipform
A system for constructing steep sided landfill sites

If the contents of this brochure do not point to a solution for a particular ribbed floor application, we urge contractors and specifiers to call our Technical Sales line on 01403 799601. Our reputation is built on innovation and we have a wealth of problem solving experience for you to call on.

Cordek Limited Spring Copse Business Park Slinfold West Sussex RH13 0SZ Telephone 01403 799600 Facsimile 01403 791718 e-mail sales@cordek.com

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