Transform Your Construction Process

Achieve Structural Excellence with Polystyrene Waffle Pods from Reozone

Elevate your construction projects with Reozone’s Waffle Pods, engineered to optimise concrete usage with precision, significantly reduce waste, and accelerate construction speed. This innovative solution minimises environmental impact by reducing soil disruption and eliminating trench excavation debris. Ideal for new residential homes, building extensions, or commercial developments.

Proudly recognised for innovation, the Waffle Pod System was awarded the prestigious Engineering Excellence Award by the Institution of Engineers Australia. It complies with the Australian Quality Standard AS 2870-2011 for Residential Slabs and Footings, ensuring your projects exceed industry standards in quality and sustainability.

Request your Free Quote today and build smarter, faster, and greener with Reozone’s Waffle Pods.

Engineer Australia Awards
Available for delivery across NSW

Waffle Pod Sizes

Waffle Pods are lightweight but strong, able to withstand the weight of numerous building workers and wet concrete during site prep and pour. Our calculation formulas can help with estimations of Waffle Pod accessories.

Reference Description Height (mm) Length (mm) Width (mm)
POD150 Polystyrene Waffle Pod 150 1100 1100
POD225 Polystyrene Waffle Pod 225 1100 1100
POD300 Polystyrene Waffle Pod 300 1100 1100
Reference Size (mm) Unit
PODSP1 Single Spacer Each
PODSP4 4 Way Star Spacer Each
Reference Description
PODDEL Pod Delivery Sydney Metro Area
PODENVIRO Environmental Levy
SCRAPBAGS Scrap Bags
PODTD Pod Tie Down with Net
Build Smarter, Not Harder

Your Premier Source for Waffle Pods in Sydney

Waffle Pods have many advantages, including optimising concrete usage and significantly reducing waste and labour-intensive processes. If strength and durability are important, trust Waffle Pods to fortify your construction, offering enduring reliability while curtailing costs.

The Waffle Pod Slab System refers to a technologically advanced method of concrete slab construction that involves building ‘on-ground’ instead of ‘in-ground’. This process removes the need for trenching, reduces building costs, and improves construction durability and strength.

Waffle Pod slabs are highly efficient in vibration control, which makes this construction method an especially good choice for buildings carrying heavy weight loads, such as commercial buildings with high amounts of traffic. However, this construction method is also helpful for any residential, commercial, or industrial building.

Using Waffle Pod slabs has numerous advantages. Here are a few reasons why they are good.

  1. Simpler, faster preparation and building process
  2. Waffle Pods use less concrete and will cost about 30% less than conventional slabs
  3. Structural stability and decreased tendency to crack
  4. Improved structure safety and longevity
  5. Easier installation of electrical wiring and plumbing pipes
  6. Less waste and a reduced environmental impact

A rigid foam layer under the concrete slabs separates the slab from the soil and provides an additional insulation layer. This foam allows for better temperature control within the building, especially in cold climates.

A Waffle Pod slab is a type of concrete slab commonly used in residential construction. It’s built by placing polystyrene pods (which look like waffles due to their grid-like structure) on a prepared level surface. These pods create a void beneath the slab, reducing the amount of concrete needed while still providing strength. Here’s how it works:

  1. Pods and Steel Reinforcement: The polystyrene pods are laid out in a grid pattern, and steel reinforcement bars (reo) are placed on top, providing strength to the slab.
  2. Formwork: Formwork is set up around the perimeter of the area to shape the slab and keep everything in place.
  3. Concrete Pouring: Concrete is poured over the pods and steel reinforcement, filling the gaps between the pods and forming the slab.
  4. Weight Distribution: The resulting slab has ribs formed by the spaces between the pods, creating a grid of concrete beams. These ribs distribute the weight evenly across the ground, improving load-bearing capacity.
  5. Insulation & Efficiency: The void created by the pods offers insulation and reduces the amount of concrete required, making it a cost-effective and energy-efficient option.

This method is quicker to install, uses less concrete, and offers excellent thermal insulation due to the air gaps created by the pods. It’s ideal for sites with stable soil conditions.

Both construction methods are useful under the right circumstances. While Waffle Pod slabs are cost-effective and easier and cheaper to construct, some builders prefer raft slabs in certain site conditions.

Raft slabs are best for:

  • Very soft ground, especially if it’s prone to movement or erosion
  • Sloping building sites
  • Areas with lots of high winds or cyclones

Calculations are simple enough when using the Waffle Pod Slab System.

  1. To find the number of waffle pods per concrete slab, you need to divide the total area m^2 by 1.51.
  2. For the number of 4-way spacers, multiply the number of waffle pods X 1.4
  3. For the number of 2-way spacers, divide the number of 4-way spacers by 3
  4. For the trench mesh chairs, divide the perimeter beam length by 1.2
  5. For the number of Bar Chairs, multiply the number of waffle pods X 3

Waffle Pod slabs, like any type of concrete slab, can be prone to cracking under certain conditions. However, when designed and constructed properly, they perform well. Some factors that might lead to cracking include:

  • Poor soil preparation: If the ground underneath isn’t compacted or leveled properly, it can settle unevenly, leading to slab stress.
  • Insufficient reinforcement: Reinforcement bars need to be placed correctly to handle the loads and stresses.
  • Extreme temperature changes: Rapid shifts in temperature can cause concrete to expand and contract, leading to cracks.
  • Incorrect curing process: If the concrete isn’t cured properly, it can weaken the slab.

Minimal concrete cover is another important factor that can make Waffle Pod slabs prone to cracking. Concrete cover refers to the depth of concrete that surrounds the reinforcement bars (rebar). If there isn’t enough cover, the rebar may be exposed to moisture, which can lead to corrosion and reduce the strength of the slab, increasing the likelihood of cracking.

Common issues with minimal concrete cover in Waffle Pod slabs include:

  • Exposure to moisture: If the rebar is too close to the surface, moisture can penetrate and cause the steel to rust, leading to cracks.
  • Inadequate protection: Minimal cover reduces the protection the concrete provides to the reinforcement from environmental factors.
  • Weaker structural integrity: The slab may not perform as intended under loads, leading to stress cracks.

To avoid this, it’s important to adhere to the recommended minimum cover, which is typically around 40-50mm depending on the environmental conditions and load factors. Proper placement and ensuring adequate concrete thickness around the rebar are essential to prevent cracking.

Overall, Waffle Pod slabs are designed to minimise the amount of concrete used and distribute loads efficiently, reducing the risk of cracking. Proper engineering is key to avoiding issues.

Slab Waffle Pod Supplier

Reozone supports the following charities and sporting teams

We’re Ready to help

Contact Us for a Free Quote Today.

Ready to discuss your project? We’re here to answer questions, provide a competitive quote, and explore how our commitment to safety, quality, and sustainability can benefit your build.

(02) 8821 7240

(02) 8821 7240

info@reozone.com.au

info@reozone.com.au

Drop files here or
Max. file size: 128 MB.