How to Install

How to Build an EPS Waffle Pod Slab: Step-by-Step Guide

Step 1

Site Preparation

To start, survey the site to confirm it is level and stable for construction. If the ground is uneven, perform necessary earthworks, such as cutting and filling, to achieve a flat surface. Ensure all plumbing and drainage systems are installed according to the building plans. Verify that connections are secure and aligned with engineering specifications. This step ensures the foundation is prepared for the installation of Hunter Pods EPS waffle pods, a crucial element in achieving slab durability and strength.

Step 1

Step 2

Formwork & Ground Preparation

Begin by constructing external formwork to define the perimeter of the slab. Spread a 50mm layer of compacted sand evenly across the area to create a stable base. Lay builder’s plastic over the sand, ensuring all overlaps, joins, and penetrations around pipes are securely taped. This protective layer prevents moisture absorption into the concrete slab, enhancing durability and thermal performance. Proper ground preparation is essential for a long-lasting and energy-efficient concrete slab foundation.

Step 2

Step 3

Spacer & Bar Placement

Position Hunter Pods spacers along the slab’s perimeter and at the designated beam locations according to the construction plans. Insert reinforcement bars into the external spacers around the perimeter and secure them using tie wire to maintain proper alignment. This setup ensures structural integrity and forms the basis for the load distribution within the slab. Careful placement of the spacers and bars is essential for achieving the required strength and stability in your EPS waffle pod slab design.

Step 3

Step 4

Waffle Pod Layout & Reinforcement

Arrange the Hunter Pods EPS waffle pods as per your engineering plans, using the provided spacers to form the ribs of the slab. Cut the pods as necessary to accommodate the dimensions of the building area or any exposed plumbing pipes. Place reinforcing bars in the beams on the spacers to ensure proper alignment. Once complete, cover the slab area with reinforcing mesh, supported by Tripod Rails or Bar Chairs as specified. This step prepares the slab for inspection and ensures optimal load distribution.

Step 4

Step 5

Managing EPS Offcuts

After placement of the the Hunter Pods EPS waffle pods, collect all offcuts and place them into the provided EPSA recycling bags. Ensure the bags are securely tied to prevent material loss or contamination. Store the filled bags in a designated area on-site, ready for scheduled pick-up by the recycling service. Properly managing EPS offcuts supports sustainable construction practices, reduces site waste, and ensures the material can be efficiently recycled into new, environmentally friendly products.

Step 5

Step 6

Inspection

Request an inspection from relevant authorities to ensure the slab complies with the National Construction Code (NCC) and Australian Standards (AS 2870) for residential slabs and footings, as well as all applicable engineering specifications. Inspectors will evaluate the layout of the pods, spacers, reinforcing bars, and mesh to confirm compliance with structural and thermal performance requirements. Address any necessary adjustments promptly. Meeting these standards is critical for safety, durability, and ensuring the waffle pod slab meets best-practice construction benchmarks.

Step 6

Step 7

Concrete Pouring

Pour the concrete carefully, ensuring it flows into the ribs between the EPS waffle pods to create a solid and evenly distributed slab. Vibrate the concrete to eliminate air pockets and ensure a consistent finish. The concrete layer should have a minimum depth of 85mm above the pods, with at least 20mm of cover over the reinforcing mesh, or as specified in the engineering plans. Proper concrete pouring ensures the structural integrity and longevity of your EPS waffle pod foundation.

Step 7

Tips for Successful Installation

Check Weather Conditions

Avoid pouring concrete during extreme weather conditions (very hot or rainy days) to ensure optimal curing.

Use Quality Materials

Ensure all materials used, including concrete mix and reinforcing mesh, meet industry standards for best results.

Follow Engineering Plans

Always adhere to engineering specifications for spacing, depth, and reinforcement placement.

Safety Precautions

Wear Protective Gear

Always wear gloves, goggles, and a hard hat when working on-site.

Proper Lifting Techniques

Use correct lifting techniques when handling heavy materials to avoid injury.

Site Safety

Keep the work area clean and free of hazards to prevent accidents.

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