CORDEK LTD
SPRING COPSE BUSINESS PARK
SLINFOLD
WEST SUSSEX RH13 0SZ
Tel: 01403 799600
Fax: 01403 791718
Suppliers of: Cellcore, Cellform, Cellvent, Heaveguard, Ventform, Puraflex, Correx, Filcor, Groundform, Corgrid, Groundform, Sideform, Pilecor, Corbreak, Formers, Trough Moulds, Waffle Moulds
Cordek provides technical solutions for a range of construction requirements. Innovative thinking, engineering expertise, and CAD/CAM capabilities enable Cordek to solve a wide variety of engineering problems. Since their formation in 1973, Cordek have worked on major iconic projects through to domestic extensions, and remain committed to supplying the best quality, value solutions, supported by the highest levels of personal service.
Cordek have a range of CAD drawings and BIM Files: click here
Cordek Construction Products
Cordek can now offer an exciting range of products that are extensively used in a variety of construction applications.
The Cordek product range is listed below by market sectors:
Ground Heave Solutions
Products for the protection of buildings from the effects of expansive soil.
VOC & Ground Gas Protection
A range of solutions for the protection of buildings from the hazards relating to VOC’s and ground gas.
Structural Fill Solutions
Expanded Polystyrene for use as a lightweight alternative to traditional fill materials, for permanent load bearing applications.
Void Formers
Used for the formation, shaping and positioning of openings to reduce the weight of concrete structures.
Standard Formwork Solutions
Falsework and Formwork systems to aid the construction of structures formed from both masonry and reinforced concrete
Permanent Formwork for Ground Beams & Pile Caps
Economical permanent formwork systems that have replaced traditional formwork materials for the construction of cast in-situ concrete foundations.
Formwork for Ribbed Concrete Floors
Established formwork systems for the construction of both one way (troughs) and two way (waffles) spanning ribbed concrete floors.
Piling Products
Solutions to common issues associated with piled foundations.
Temporary Access & Protection
Access/ protection solutions for construction and refurbishment works.
Cordek offers additional services for design and construction of bespoke formwork and patterns & moulds, as well as a range of Comprehensive Continuing Professional Development (CPD) Seminars for Architects, Contractors, Designers, Engineers and Specifiers. Our technical experts are happy to visit you at your convenience to hold a CPD session.
The CPD Seminars available include:
- Bespoke Formwork
- Cordek Solutions
- Lightweight Structural Fill & Void Forming
- VOC & Ground Gas Protection
For more information please visit www.cordek.com or email contact@cordek.com
Further technical information including; Data Sheets, Standard Details and Certifications of Approval is available from Cordek’s Technical Library here
Cordek Rubber Formwork Liner - Great Eastern Quays
The historic London Royal Docks have been undergoing a three-phase regeneration which includes the formation of new residential, commercial and leisure areas. The Great Eastern Quays scheme is part of this regeneration project,and during the construction, Cordek was brought on board to provide a formwork solution for feature balconies on one of the new apartment developments.
Cordek were approached by the concrete frame contractor Modebest to provide a formwork solution for creating a ‘scalloped’ profile to the underside of the cast in-situ concrete balconies. The proposal was to provide rubber formwork liners supported by a plywood deck/props for multiple re-use.
The solution comprised of supplying formwork liners manufactured from Reckli 45 poured in liquid form in to model board moulds, machined using a 5-axis router. Once cured, the formwork liners were demoulded and supplied to site in three units, two of them standard (re-used multiple times) and one bespoke to suit the required shape and dimensions of the individual balcony type. Joints in the formwork liner were hidden so that the specified smooth, blemish free finish was achieved in the exposed concrete. In total there were approximately 300no. balconies with a maximum size of 7.1m x 1.8m.
Cordek Supplied Filcor 100 - M4 Junction 3-12 Motorway Upgrade
The M4 Junction 3-12 motorway upgrade project, which started construction in July 2018, is designed to increase capacity, and reduce congestion between Junction 3 (Hayes) and Junction 12 (Theale). In the sections where there is no pre-existing hard shoulder for conversion into an additional running lane, a total of 11 overbridges needed to be demolished and replaced with longer decks to enable continuity of the widened carriageway.
The £848m project is due for completion in Spring 2022, by which time it is expected that approximately 680,000t of material will have been excavated, 1.8M.m² of new surface laid, 130km of cabling installed and 63km of concrete barrier positioned.
Cordek were approached by the Principal Contractor Balfour Beatty VINCI joint venture to provide a lightweight structural fill solution to be used for the embankment construction adjoining the Datchet Road Overbridge, between Junction 5 and Junction 6.
Project Scope
It was identified that beneath the proposed location for the Datchet Road Overbridge embankment, lay a localised area of peat deposits which provided concerns over potential settlement and subsequent impact on the carriageway adjoining the bridge. Additionally, underlying HV cables and the requirement to reduce the influence from the embankment construction above, led the project designers to conclude that a lightweight structural fill solution was required.
The Solution
Due to the ongoing COVID-19 pandemic at the time, all discussions between Cordek and Balfour Beatty VINCI were undertaken remotely and therefore relied upon the use of digitally shared design information to determine the project requirements.
The use of 3D BIM modelling techniques indicated that from formation level to the deepest point of the lightweight structural fill was approximately 5.0 metres, which terminated around 1.2 metres beneath the surface of the proposed carriageway. Further scrutiny of the 3D model suggested that a total volume of 4,070 m³ of material would be required, in the form of Filcor 100 Expanded Polystyrene (EPS) blocks.
The project designers determined that Filcor 100 provided the optimum combination of lightweight properties at only 35kg/m³, with a compressive strength capable of withstanding the loadings attributable to the embankment construction with minimal deflection. Furthermore, the use of Filcor 100 within the embankment removed the requirement for compaction or earth moving plant, allowing the ambitious programme for installation to be met.
Each Filcor 100 block was supplied with the dimensions 2400mm x 1200mm x 600mm and installed in staggered layers to aid stability whilst exposed. Where cutting of the blocks was required, this was undertaken using Cordek’s 110v portable Hot Wire Cutters that were provided to Balfour Beatty VINCI on a hire and return basis.
Summary
Despite the COVID-19 restrictions in place at the time and the relatively short lead-in to the project, Cordek supplied the 4,070 m³ of Filcor 100 required by the means of 59 fully loaded articulated lorries in just over five weeks, meeting the contractor’s construction programme without delay.
Whilst this element of the project was undertaken in the Autumn of 2020, Balfour Beatty VINCI is expected to complete the whole M4 motorway upgrade scheme on behalf of their client Highways England, during spring 2022.
