MOULDS

A range of polypropylene
Trough & Waffle Moulds
 WR
Polypropylene Trough & Waffle Moulds

Injection formed polypropylene trough and waffle moulds were originally introduced
to the market some forty years ago by GKN, as a cost effective solution for
constructing in-situ ribbed concrete floors. Since that launch the range has been
developed and refined and is available throughout the world in eleven standard sizes.
Still known as T Forms (troughs) and M Moulds (waffles) the products are now
marketed by W R Moulds (UK) Ltd, a wholly owned subsidiary of Cordek Limited.

T Forms M Moulds
for one-way spanning floors for two-way spanning floors

Polypropylene moulds are suitable for a wide variety of

buildings, and specifiers now have a considerable choice
when designing cost effective in-situ ribbed floors.
The trough moulds offer a good
quality industrial finish.

Waffle moulds with their butting

flanges provide a very economic and
aesthetically pleasing finish, which
can be left exposed or painted.

In the UK and Ireland all moulds are hired on weekly or contract rates. Elsewhere in
the world they are generally purchased, although in certain circumstances hire terms
can be made available.

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 8M & 9M
Polypropylene Waffle Moulds

WR Moulds have a comprehensive range of waffle moulds for constructing two-way

spanning rib concrete floors.The mould design is square in plan for quick and easy
use and is compatible with full-decked support systems.

Features of 8M & 9M waffles

● Available in 7 standard sizes
● Up to 100 uses per mould
● Provides an excellent ‘feature’ finish
● Lightweight, durable and easy to handle
● Available on very short lead times
● Moulds ‘nest’ for storage and transportation
● Significant concrete saving compared with solid floors
● Good thermal characteristics

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All waffle moulds are supplied with butting flanges and provide a cost effective
way of reducing concrete and steel requirements.
The finish is very attractive and is often left exposed. It can also be painted or
designed to include special lighting.

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 8M & 9M
Polypropylene Waffle Moulds

Essential information for the Specifier:

8M Mould - 800mm RIB CENTRES Dimensional Data (mm)

Void Volume Void Volume R 88 12o 2'
Depth Weight of mould per m2 of floor
mm kg m3 m3

400
R 19

300
200 5.00 0.0765 0.120

250
200
250 5.40 0.0927 0.145
62.5

depth 19
300 5.75 0.107 0.167

Flange
800
400 7.25 0.135 0.211
62.5

800
62.5
125 approx.
800 ribs in both directions

9M Mould - 900mm RIB CENTRES Dimensional Data (mm)

R 100 11o 19'
Void Volume Void Volume
Depth Weight of mould per m2 of floor
mm kg m3 m3
425

R 25
325
225

225 9.30 0.116 0.143

325 11.40 0.158 0.195 62.5

depth 25
Flange

425 13.40 0.199 0.240 900

62.5
900
62.5

125 approx.
900 ribs in both directions

NOTE: MAXIMUM TOPPING IS 175mm.

If a larger topping is needed please consult our technical services dept.

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EXAMPLE

The volume of concrete used per m2 of floor is calculated as follows:

For this example assume: that the floor has ribs at 900mm centres (9M mould)
that the mould is 225mm deep
there is 100mm of topping
i.e. total depth = 325mm

Total volume per m2 of floor = 1.0 x 1.0 x 0.325 = 0.325 m3

Void volume per m2 of floor (table opposite) = 0.143 m3
So, volume of concrete per m2 is 0.325 - 0.143 = 0.182 m3

SUMMARY

The 8M & 9M range offers designers a comprehensive The lead time on manufacturing new moulds is only a
choice of polypropylene waffle moulds for constructing matter of weeks, which enables WR to quickly satisfy
two-way spanning floors. Substantial stocks are held on the demands of export markets.
all sizes, to ensure a rapid and reliable delivery service.

If our standard waffle sizes do not meet the specifiers requirements please contact
our Technical Services Dept.

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 T FORM
Polypropylene Trough Moulds

The T Form mould system was developed for constructing one-way spanning ribbed
concrete floors.

Features
● Made in 4 standard depths
● Up to 100 uses per mould
● Provides a good industrial finish
● Lightweight, durable and easy to handle
● Available on very short lead times
● Up to 60% concrete saving compared with solid floors
● Significant savings on steel reinforcement
● Suitable for high temperature environments

The basic system consists of two units which

interlock to form a trough.

‘A’ Unit ‘B’ Unit

Every trough consists of a multiple of A units,

plus one B unit, to form the required length.

Adjustment All Dimensions in mm Adjustment

100 565 50 655
o 10o approx.
7 R 75 7o

DEPTH
R 19 R 15 (See Table)
R 19
Flange
25

750 600 745

‘A’ UNIT SECTION ‘B’ UNIT

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T Form Characteristics

Trough Weight Depth Rib Width Rib Centre

Type kg mm mm mm 10o approx.
R 75

D1 3.50 175 125 600

D2 4.14 250 125 600 R 15

D3* 4.78 325 125 600

D4* 5.42 400 125 600 475

600
* These require diaphragms to prevent deflection - see page 8
All Dimensions in mm

A new feature of the T Form system is the introduction

of butting flanges for all mould sizes.
While Rib Centres remain at 600mm, the new wider flanges bring a number
of benefits; timber in-fills are no longer necessary, resistance to deflection is
increased and the rib finish is much improved.

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 T FORM
Polypropylene Trough Moulds

ACCESSORIES

Diaphragms End Closer Clips

Decking Beam

End Closer Clip

Diaphragms

Diaphragms prevent deflection. End Closer Clips are used to maintain

They are incorporated in D3 and D4 Units the trough length
(one per ‘A’ unit, 2 per ‘B’ unit)

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Essential information for the Specifier

T Form Concrete Concrete Maximum

Type displacement displacement Topping**
per linear metre* per m2* mm

D1 0.076 0.127 150

D2 0.106 0.177 150

D3 0.134 0.224 150

D4 0.160 0.267 150

* Assuming a standard 125mm rib width

** If a larger topping is needed then consult our technical services
department

EXAMPLE

The volume of concrete used per m2 of floor is calculated

as follows:
This example assumes: that the floor will be formed using D3 moulds
D3 moulds are 325mm deep (see table above)
there is 150mm of topping
i.e. total depth = 475mm

Total volume per m2 of floor = 1.0 x 1.0 x 0.475 = 0.475 m3

Void volume per m2 of floor (table above) = 0.224 m3
So, volume of concrete per m2 is 0.475 - 0.224 = 0.251 m3

SUMMARY

The T Form trough system provides the specifier with a very cost effective
solution for the construction of one-way spanning floors.
Depending on project requirements the moulds can be either hired, or
purchased on a buy-back agreement.The substantial stockholding on all sizes
ensures a rapid and reliable delivery service.

If the 4 standard sizes do not meet the specifiers requirements, please contact our
Technical Services Dept.

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MOULDS
WR Moulds (UK) Limited
Aurillac Way, Hallcroft Industrial Estate
Retford
Nottinghamshire DN22 7SS
England
Telephone +44 (0) 1777 708432
Facsimile +44 (0) 1777 860383
e-mail enquiries@wrmoulds.co.uk
Website www.wrmoulds.co.uk

WR Moulds (UK) Limited is a wholly owned

subsidiary of Cordek Limited, Europe’s largest
manufacturer of specialist expanded polystyrene
products for the construction industry.
Cordek Limited
Spring Copse Business Park
Slinfold
West Sussex RH13 0SZ
England
For more information on non-standard
Telephone +44 (0) 1403 799600 trough and waffle moulds please contact
Facsimile +44 (0) 1403 791718 the Cordek Technical Department,
on +44 (0) 1403 799601
e-mail sales@cordek.com
Website www.cordek.com

The contents of this brochure are the copyright of Cordek Limited

and may not be reproduced without permission. November 2002