WAFFLE MOULDS – AREA OF USAGE
Waffle moulds are generally used for the projects those have a wide spanning area of more than 8m. Buildings such as, hospitals, shopping malls, multi storey car parks, conference rooms, industrial facilities, wide logistics areas etc.
The waffle moulds are generally in small square form and offers designers a comprehensive choice of fiberglass waffle moulds for constructing two-way spanning floors for a very high loadbearing. By means of waffle design concrete slabs easily bears its own load and other dinamic loads.
Waffle mould with the main material of fiberglass has an excellent design elasticity for either small (ex. 70cm) or big (ex. 270cm ) dimensions. In contrast with the general polypropylene materials, fiberglass has the Heat Deflection Temperature (HDT) range under strenght more than 80C (degree) up to 150-200C. By means of this characteristics with the suitable fiberglas content there is no risk of cracking in cured concrete. In addition to this, fiberglass mould has the advantage of extra reinforcement in designing iner construction with iron and wood material. It is very normal and theoritically possible to make a 1 m2 mould to bear the concrete load of more than 1000kgs. During the time concrete goes to cure temperature and also towards the cool down there ocur minimal behaviors in mould harm to concrete. This is the main risk and likely to occur in nonreinforced plastics.
Fiberglass trough and waffle moulds were introduced to the market as a cost effective solution for constructing in-situ ribbed concrete floors.
Since that launch the range of dimensions in trough and waffle moulds has been developed a lot and now is available in more than 40 standard sizes in our production scope. T Forms (troughs) and M Moulds (waffles) are produced and marketed by Teknik Fiberglas San. ve Tic. Ltd. Şti.
INSTALLATION AND APPLICATION
Waffle moulds can be used with all types of scaffolding system. But the spindles with U heads advised. After the assembly of base plates for main beams, H20 beams must be placed on slab area. H20 beams must be placed according to waffle dimensions and grid area. Then waffle moulds are ready to be placed on H20 beams. A suitable mould release agent applied on the mould surfaces after the placement. Then iron structure can be formed by spinning. The final stage is concreting.
DEMOULDING PROCESS
For a good and easy demoulding operation mould release agent must be properly applied before concreting. Because of minimal bending and deformation under certain temparature and pressure when the concrete cures, demoulding operation needs the help of air pressure. This situation is not so safe like fiberglas when used any thermoplastics material in the mould. Later you can see a lot of cracks in the concrete.
Operator must apply air pressure through the hole on the mould by means of an air gun. There must be used compressor with a sufficient capacity and air pressure at least 8Psi. It is very useful to clean the moulds with a medium pressure water jet and a soft brush as soon as possible after demoulding.
The moulds are not indestructible. They must be saved against the direct sun shine and rain when stocking a long time. The best way in standing is horizontally nested position when you need them stacked with a minimum area usage. If this is not possible they must be stacked one on another in the position like they are placed on the slab. In order to be faced minimum distortion during long time stocking the minimum must be the stacking.
SPECIFICATIONS AND THE ADVANTAGES OF FIBERGLASS WAFFLE MOULDS
1-The most known and known type of waffle moulds.
2-The most cost effective way of production even the demand is very low. 10pcs production can be applied profitably.
3-Has a limited design elasticity, no problem what you need.
4-Can be produced and modified easily by hand.
5-The main material is glass fiber and the exposed surface is very hard, smooth and shiny better than the alternatives.
6-Has the advantage of extra reinforcement with iron or wood against the outside pressure.
7-Has the elasticity of strenght modes by changing the material, thickness and the process.
8-Easy to demoulding
9-Life of the mould can be well in excess of 50 uses with no deflection and bending under concrete.
10-Lighter than metals and heavier than thermoplastics.
11-All projects can be applied with no restriction.
12-Easy to repair and not costly.
13-Ideal for rigidity and elasticity for a mould.
14-Maximum heat deflection temperature with minimum bending under curing condition. Best advantage against thermoplastics.
15-Has a good and familiar second hand value in market.
16-The finished floor provides an attractive visual feature beter than the alternatives.