1. The Wafflemat™ Foundation Forming System On-grade Mat Foundation for Expansive, Collapsible and Rocky Soils

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Upfront
The Wafflemat Foundation-Forming System
What it is – and isn’t
Features
Typical installation steps
‘How To’
Photo Sequences
Technical resources
Contacts
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Description
What it is
Elevated post-tension slab (4” to 6”) poured monolithically over either 8.5” or 12” high, 19” x 19” foundation forms (‘Waffleboxes’), which provide void space for movement of soils
A series of ribs, 3’8” on center, are created by inter-connecting the foundation forms
What it’s not
Slab resting entirely on grade, made entirely of concrete, without a place for movement of soils
Dirt-formed rib system requiring significant trenching and construction
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4. It is

5. is not... 5

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Section View
Top View
Cross Section
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7. Features Design: Performance: Implementation: References:
Use on expansive, collapsible, and rocky soils.
Performance:
Voids resist swelling from over-watering, surface drainage, and flooding. Ribbed footprint means less contact with soil, yet extremely stiff slab. Prefect placement of cables equals minimum sag/additional strength. Acts as built-in vapor barrier.
Implementation:
No presoaking pads, no trenching for concrete beams, no footings, no earth spoils and off- haul. Less depth of trenching for plumbing laterals beneath foundation forms. Quick -- and, fool proof -- set up/installation.
References:
- Millions of sf residential & light commercial space installed since 1995 in most difficult soil conditions in US and Mexico without one structural callback/failure.
One More: Made of “green” (re-cycled polypropylene plastic) materials
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8. Typical Installation Cycle
Day 1: Form boards set, plumbing installed, inspection
Day 2: On-grade mat foundation forms (‘Waffleboxes’) spread and clipped/connected
Two sizes of void boxes; 8.5” uses plastic clips, 12” metal clips
Place tendons/anchor bolts
Set interior form; i.e., garage firewall / porch
Inspection
Day 3: Slab poured
Strong enough for crew to walk on
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‘How To’
Estimate number of Wafflebox foundation forms in footprint
Take total sf of footprint, divide by 4.15
Example: 1500 sf / 4.15 = 361 Waffleboxes needed
Calculate number installed per man hour
Detailed survey of last 15 projects; most 175 per man hour, least 28 per man hour, average 75 per man hour
Determine yards of concrete in a Wafflemat slab
28 sf per cubic yard using 8.5” Wafflebox w/ 5” slab
Example: 1500 sf / 28 = 54 yards
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10. Setup

11. Setup

12. Groups of two/four Waffleboxes clipped & connected12

13. Slab Pour

14. Finish

15. 5,000 sf house in Hawaii

16. Note: Plumbing already up16

17. Waffleboxes left out for point loads17

18. Cables in Clips

19. Strong enough to walk on

20. Working in Hawaii

21. Waffleboxes ‘lock’ when concrete poured

22. Used on Multi Levels

23. Finished House

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Technical Resources
Wikipedia: Grade_Mat_Foundation_for_Expansive_Soils
Google: ‘On-grade mat foundations’
Best Base Website → ‘Technical Papers’
Wafflemat Slabs Provide Superior Performance
Lowering the Carbon Footprint When Using the Wafflemat System for Concrete Slab Foundations
Wafflemat System Design Considerations
Wafflemat FAQ
Thermo Mechanical Analysis of Wafflemat Samples
Wafflemat and the IBC
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Contacts
Tom Richards,
Jim Winslow, Implementation:
Rich Treanor, Planning/Production:
Tom Bragg, Engineering Liaison:
John Cook, S.E.:
Dan Rhoades, G.E.:
Greg Carr, P.E.:
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