Setting the formwork, tying the steel, pouring the concrete before dismantling everything to reveal the finished product - a flat, concrete surface.

The problem is that after a few uses the form-ply becomes unusable and - non-recyclable.

Now Australian engineering company DCI has come up with a revolutionary suspended flooring system that is made from BHP galvanized steel, reusable and 100 percent recyclable.

DCI Director, Andy Stodulka - a structural engineer who, for years, has pondered over the idea of a practical and reusable forming system, created the worldwide-patented invention. A system which would allow significant reductions in material, labour and costs, at the same time enhancing the slab’s appearance and structural integrity.

The result  - “CORCON” - fast - cost effective - reusable. An innovative use of BHP steels creating an appealing and highly functional concrete flooring system!

Set up begins with the beam moulds. The combination of bearers on formwork frames - provides adequate support for the beam moulds set at 1200mm centres.

CORCON floors can support twice the span for the same volume of material compared to conventional flat slabs, using half the scaffolding.

Span Requirement Being Accommodated

An overlap gives the beam moulds a telescopic capability, allowing for spans of up to 9 metres with simple reinforcement - and up to 26 metres if prestressed post-tensioned.

Shot of Bracket

The rib beams are stabilised by special brackets placed at either end and under the overlap, at not more than 2.4 metres centres.

Beam mould being trimmed to suit angle

Beam angles are accomplished by mitred the bottom moulds as required and by bridging any remaining space with plywood.

Cut  away of cut beam mould - show trimming of damaged beam mould

Reversing the beam mould can still use a mitred bottom beam mould. End damaged beam moulds can simply be trimmed square.

With the beam moulds now in place, the curved steel sheets are added, possible even from an intermediate platform. The process is made easy by the geometry of the system and is fast because it is repetitive.

Placing of end moulds

Steel plates, or cut plywood end moulds ensure the beams attach neatly into the transfer beams.

Placing of steel

percent in concrete and 80 percent in reinforcement steel are possible.

Rods overlapping in the centre

Bottom reinforcing rods overlap in the beam moulds providing additional strength, and resistance to deflection.

Placing of PVC inside mould - and on top slab

Once set out, incorporating fire collars, ducting and other penetrations into the slab is a very simple process, both in the beam moulds and through the upper surface.

Bolts and timber battens inserted into bottom of mould

Provision for ceiling fixtures can be incorporated into the system in a number of ways.
Alternatively power-activated tools could be used to achieve similar results, with 50 percent fewer fixing points required for the slab soffits.

Concrete pour

With the reinforcement in place and form release agent applied, the concrete is poured.

Close up of concrete running over corrugations

The overlapping of the corrugated sheets, with the last corrugation pointing down, reduces any concrete from seeping through.

Concrete is vibrated at no more than 100 to 120 mm slump into rib beams.

Dismantling, Removal of beam moulds

When the concrete is set, the simple dismantling process begins. First the beam moulds are removed, unlocking the corrugated sheets.

(Close up) Rounded corners make this an easy process and reduce the risk of damaging the Corcon system.

After all, the longer the Corcon lasts the greater the cost efficiency.

Stripping of corrugated sheets

Slab Sofit K.L. After CORCONâ   removed & Ready for Re-use

The curved sheets are stripped away, revealing the self-supporting arched slab between the beams.

This self-supporting arch is a characteristic, which allows Corcon to achieve maximum loadings and fire ratings for minimum thickness of concrete, reinforcement for minimum deflection and torsion.

Storage: formwork being placed in crates

Storage is as simple as CORCON  is designed to stack in special crates, minimising storage space and cranage and allowing the reusable formwork to be easily transported with a minimum of damage. CORCON  entails 80 percent less volume and a 50 percent reduction in weight when compared to ply.