Introduction to the Waffle-Crete Precast Concrete Building System


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The versatile Waffle-Crete building system makes it uniquely possible to construct attractive, disaster-resistant, reinforced concrete buildings in a fraction of the time and with half the raw materials of solid panels of the same thickness.

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  • This is the project that sold PII on Waffle-Crete They were able to use local labor Completed construction in record time – even thought they never used the system before The speed of erection and much lower material costs enable them to also come in well below budget for the project
  • Many other companies have recognized the Waffle-Crete benefits around the world Here is a sampling of some of projectsThe system has been used for a wide range of projects and projects sizes in a wide range of conditions From a small building here in Hays (Sternberg Museum) to a monstrous 16,000 unit apartment project in Guatamala PII cast the panels for the officer housing in Kwajalein and shipped them in for erection. Days Inn built 27 hotels in The Philippines – one of them was stairstepped down the rim of a volcanoThe government housing in Indonesia required extensive testing in a seismic simulation lab before the system was approved for construction.
  • The Waffle-Crete system is very flexible. It has been used to build structures in a variety of sizes and shapesHere is an expanded list of the applications our customers have used the Waffle-Crete system for
  • Introduction to the Waffle-Crete Precast Concrete Building System

    1. 1. Overview of the Waffle-Crete® Building System 1 Disaster Resistant Construction Faster, Greener & More AffordableWaffle-Crete International, Inc. 12/1/2011
    2. 2. More than 1.6 billion people in developing countries around the world currently live in unsafe, substandard housing. ~ A United Nations Human Settlement Program StatisticWaffle-Crete International, Inc. 2 12/1/2011
    3. 3. Urban Populations Living in Slums 3 THE NUMBERS ARE EXPECTED TO DOUBLE IN THE NEXT 20 YEARS!Waffle-Crete International, Inc. STRICTLY CONFIDENTIAL
    4. 4. The Risks of Substandard Construction 4Waffle-Crete International, Inc. 12/1/2011
    5. 5. This Could Have Been Avoided!! 5Waffle-Crete International, Inc. STRICTLY CONFIDENTIAL
    6. 6. The Global Housing Dilemma 6  Durable housing construction costs too high  Conventional construction takes too long  Skilled workers are hard to come by THE WAFFLE-CRETE BUILDING SYSTEM ADDRESSES ALL OF THESE ISSUES!Waffle-Crete International, Inc. 12/1/2011
    7. 7. The Waffle-Crete Solution 7 Gov’t subsidized housing, Indonesia Office Building, California AFFORDABLE DISASTER-RESISTANT CONSTRUCTIONWaffle-Crete International, Inc. 12/1/2011
    8. 8. The Waffle-Crete Advantage 8 When compared to conventional brick & block construction, the Waffle-Crete precast concrete building system will:  Reduce material & labor costs  Slash construction time  Eliminate the need for skilled labor  Very low life cycle cost (low ongoing maintenance) Waffle-Crete International, Inc. 12/1/2011
    9. 9. The Waffle-Crete Advantage 9 Insulated Waffle- At the heart of the Waffle- Crete Curing Cover Crete Building System Insulated Waffle- Crete Mold  Waffle-Crete molds are lightweight and portable  Concrete panels can be cast right on the job site  Panels can be cast one day and erected the nextWaffle-Crete International, Inc. 12/1/2011
    10. 10. Unparalleled Construction Speed 10 Wall, floor and roof panels can be cast while the building site is prepared. At a central casting facility Or Directly on the Job SiteWaffle-Crete International, Inc. 12/1/2011
    11. 11. A Typical 6m Waffle-Crete Wall Panel 11 An entire side of a house can be cast in one panelWaffle-Crete International, Inc. 12/1/2011
    12. 12. The Strength Is In the Ribs! 12 The vertical ribs act like columnsWaffle-Crete International, Inc. 12/1/2011
    13. 13. The Strength Is In the Ribs! 13 The horizontal ribs act like beamsWaffle-Crete International, Inc. 12/1/2011
    14. 14. The Strength Is In the Ribs! 14 Up to 60% of the concrete and steel is eliminated between the ribs.Waffle-Crete International, Inc. 12/1/2011
    15. 15. 60% Less Material Without Loss of Strength 15 “Waffle-Crete panels retain the design strengths of traditional precast panels, yet are 60% lighter than standard panels of the same thickness.” Stephen Andrews Certified Structural EngineerWaffle-Crete International, Inc. 12/1/2011
    16. 16. Waffle-Crete Weathered Hurricane Katrina 16 “We have used your molds for over ten years and built large grocery stores, multi story office buildings and small storage buildings with your concrete bolt together system. “We built multiple buildings in New Orleans, which went through hurricane Katrina. None of the buildings suffered major damage. There was no wind damage to any of our buildings in that incident.” Chester Miller Alfred Miller Contracting Louisiana, USWaffle-Crete International, Inc. 12/1/2011
    17. 17. Panels Meet Rigorous Int’l Test Standards 17PASSED ICBO Evaluation (US structural bldg standards)   Performed by ICBO Evaluation Service  Comply with 1997 Uniform Building Code & 2000 Int’l Residential CodePASSED Floor Panel Load Test   Performed by Bucher & Willis, Kansas City, MO  Complied with ACI318-71 building codePASSED Agrement Series, South Africa   Performed by Hugo & Partners, S. AfricaPASSED Seismic Testing   Performed by Research Institute for Human Settlement, Jakarta, Indonesia  Approved for Seismic Zone 3PASSED Seismic & Structural Strength Testing`   Performed by Testing Engineers, San Diego, CA  Panel strength in excess of design and local seismic loadsPASSED Fire Endurance Testing   Performed by Consulting Engineers Group, Glenview, IL  Met CAN4-S101 and ASTM E119 standards (2 hour interior rating)Waffle-Crete International, Inc.
    18. 18. Anatomy of a Waffle-Crete Mold 18 Impact & UV Rigid Extruded ResistantAluminum Rails ABS Plastic Fully Insulated Mold & Curing Cover Cutaway of Waffle-Crete mold & curing cover with wire mesh and rebar reinforcement installed  Waffle-Crete molds are lightweight and portable and useful for all kinds of projects.  A typical mold can be used up to 500 times before needing repairs or replacement.  With care, curing covers will last indefinitely.Waffle-Crete International, Inc. 12/1/2011
    19. 19. Mold Shipment & Delivery 19 Waffle-Crete molds can be shipped anywhere in the world by ocean container (left), then trucked to their final destination (above).Waffle-Crete International, Inc. 12/1/2011
    20. 20. Waffle-Crete Can Involve the Local Community 20  Local unskilled workers can be trained in hours.  No carpenters, masons, welder s or other skilled labor is needed. Government subsidized apartments constructed in GuatemalaWaffle-Crete International, Inc. 12/1/2011
    21. 21. Panels Go Together Quickly & Easily 21  Unskilled workers can erect panels as well.  A team of four workers can erect up to 25 Waffle-Crete panels a day.Waffle-Crete International, Inc. 12/1/2011
    22. 22. First Waffle-Crete Project in the Marshall Islands 22 PII chose Waffle-Crete because it makes concrete construction on the islands faster and more affordable. PII erected its first Waffle- Crete building (a 24-unit, 3- story apartment complex) in a record six days. Completed Well Ahead of Schedule and Under Budget Waffle-Crete International, Inc. 12/1/2011
    23. 23. Entire Communities Go Up in Record Time! 23Waffle-Crete International, Inc. 12/1/2011
    24. 24. Products We Sell 24 Wall and floor molds Insulated curing covers Accessory molds  Grade beam, stairs and eave trim Specialized casting equipment  Panel and cover lifters, screeds, blockouts Specialized casting supplies  Bolt & notch formers & Nifty Nailers® Waffle-Crete International, Inc. 12/1/2011
    25. 25. Waffle-Crete Panels Produced 25 Standard wall panel  Harmonized wall panel  Standard floor/roof panel 15 & 20 cm thicknesses  Shown w/door & window blockouts  15, 20 & 30 cm thicknesses  Waffle-Crete molds available in a range of standard sizes up to 10 meters  Molds can also be fabricated in custom sizes  Length & width can be reduced with wood or steel blockouts  Rail extenders can be added for insulated sandwich panelsWCI CONFIDENTIAL 12/1/2011
    26. 26. Key Waffle-Crete Specs 26 24 hour compressive strength: 2,500 psi to de-mold 28 day compressive strength: 4,000-5,000 psi* Max wall height (15 cm): 6 m* Max wall height (20 cm thick): 9.7 m*Max unsupported 20 cm floor span: 6 m* Weight of 15 cm panels: 875 kg/sm Weight of 20 cm panels: 1,112 kg/smTime to cast an 2.4 m x 4.8 m panel: 8 man hours* Rate of erection for 4-man crew: 20-25 panels/day* * Approx benchmark that can vary based on application and other factors.Waffle-Crete International, Inc. 12/1/2011
    27. 27. Waffle-Crete in 30 Countries Worldwide 27RESIDENTIAL GOVERNMENT Subic Bay housing (Philippines) –  Sternberg Museum (Kansas) 1000 units  Gov’t Apartments (Indonesia) – 600 Papelera Apartments (Guatemala) – units 16,000 units  Gov’t low income housing (Indonesia) Savitur Townhomes (Trinidad) – 500 – 1,000 units units  Officer housing – Kwajalein, Marshall IslandsCOMMERCIAL Cebu City (Philippines) – 5-story office LARGE BUILDINGS building  Nelson Arena (Canada) Cineplex Oden (Canada) – 8 theaters  Distribution Warehouse (New Mexico) Silver City Theaters (Canada) – 20 – 200,000 sq. ft. theaters Southgate Trade Technology Building HOTELS/MOTELS (Canada)  27 Days Inn Hotels (Philippines) – 50 Kelowna Business Center (Canada) to 150 rooms Franklin Supply Warehouse (Canada)  Outrigger Hotel (Majuro) – 150 roomsWaffle-Crete International, Inc. 12/1/2011
    28. 28. What Can You Build With the Waffle-Crete System? 28 Several Examples Follow:WCI Waffle-Crete International, Inc. 12/1/2011
    29. 29. Large Buildings… 29 Zone 4 Seismic 175 mph winds Subic Bay Apts. (1000 units) - PhilippinesWCI Waffle-Crete International, Inc. 12/1/2011
    30. 30. …Small Buildings… 30 Restroom Facilities – Hays, KSWCI Waffle-Crete International, Inc. 12/1/2011
    31. 31. …Low Income Housing… 31 Row House in The Philippines Model Home in JamaicaWCI Waffle-Crete International, Inc. 12/1/2011
    32. 32. …Retail Buildings… 32 Shopping Center - Alexandria, LouisianaWCI Waffle-Crete International, Inc. 12/1/2011
    33. 33. …Relocatable Buildings… 33 Hazardous Materials StorageWCI Waffle-Crete International, Inc. 12/1/2011
    34. 34. …Conventional Buildings… 34 Hampton Inn – Washington, D.C.WCI Waffle-Crete International, Inc. 12/1/2011
    35. 35. …And Some Unconventional… 35 Artificial Reefs – US East Coast > Manure Tank – KansasCooling Towers @ Biosphere II – ArizonaWCI Waffle-Crete International, Inc. 12/1/2011
    36. 36. …Even on the Rim of a Volcano… 36 Philippines – Day’s Inn ResortWaffle-Crete International, Inc. 12/1/2011
    37. 37. …And to Keep People Out & Landfill In. 37 Barrier Wall – Ellis County Power Plant, Kansas Earth retaining wall - Albany, New YorkWaffle-Crete International, Inc. 12/1/2011
    38. 38. Sometimes the Waffles are Invisible… 38 Days Inn/General Santos Hotel – PhilippinesWCI Waffle-Crete International, Inc. 12/1/2011
    39. 39. …Sometimes They Show on the Outside… 39 Warehouse in Kansas City Office Building in CaliforniaWCI Waffle-Crete International, Inc. 12/1/2011
    40. 40. …And Sometimes on the Inside. 40 Low IncomeHouse Interior Pep Boys Auto Parts Store – Puerto RicoWCI Waffle-Crete International, Inc. 12/1/2011
    41. 41. More Examples of Waffle-Crete Projects 41 Warehouse Exteriors with Waffle-Crete wall panelsWCI Waffle-Crete International, Inc. 12/1/2011
    42. 42. More Examples of Waffle-Crete Projects 42Steel columns supporting Roof Waffle-Crete panels supporting roof Waffle-Crete panels used as a curtain wall WCI Waffle-Crete International, Inc. 12/1/2011
    43. 43. More Examples of Waffle-Crete Projects 43Officer Housing –Kwajalein Military Base Middle Income Apartments - MajuroWCI Waffle-Crete International, Inc. 12/1/2011
    44. 44. More Examples of Waffle-Crete Projects 44Examples of Waffle-CreteOffice BuildingsWCI Waffle-Crete International, Inc. 12/1/2011
    45. 45. More Examples of Waffle-Crete Projects 45Examples of middle incomeapartment complexes in the USWCI Waffle-Crete International, Inc. 12/1/2011
    46. 46. More Examples of Waffle-Crete Projects 46 Marriott Hotel, Kansas CityWCI Waffle-Crete International, Inc. 12/1/2011
    47. 47. Waffle-Crete Applications Abound 47TRADITIONAL SPECIALTY Mass housing  Parking Structures Commercial  Storage Tanks Government Buildings  Cooling Towers Motels/Hotels  Barrier/Sound Walls Warehouses  Retaining Walls Manufacturing Facilities  Artificial Reefs Movie Theaters  Relocatable Bldgs Condominiums  Haz Mat Storage Medical Centers  PrisonsWCI CONFIDENTIAL 12/1/2011
    48. 48. Waffle-Crete Recap 48 Portable precast concrete forming system Useful for a wide range of building types Cuts concrete & steel by up to 60%  More sustainable solution Provides superior structural strength Requires no skill and minimal training Dramatically accelerates construction speedWaffle-Crete International, Inc. 12/1/2011
    49. 49. There Is No Need For This To Happen Again! 49Waffle-Crete International, Inc. STRICTLY CONFIDENTIAL
    50. 50. For More Information 50 www.waffle-crete.comWCI Waffle-Crete International, Inc. 12/1/2011