Airdeck is a construction system that uses hollow, ball-shaped plastic void formers placed inside concrete floor slabs to replace non-structural concrete in the core of the slab. By creating air pockets within the concrete, Airdeck significantly reduces the weight of the floor while maintaining its structural strength and load-bearing capacity.
How it works
Airdeck void formers are spherical or elliptical hollow plastic balls, typically made from recycled polypropylene. During construction, these balls are positioned in a grid pattern between the top and bottom layers of reinforcement in a concrete slab. Once the concrete is poured, the balls remain permanently embedded, displacing concrete in the middle of the slab where it contributes least to structural performance. The result is a biaxial voided slab that behaves structurally like a solid slab but with substantially less mass.
Application
Airdeck technology is used in a wide range of building projects:
- Flat slab construction — Office buildings, apartment blocks, and commercial structures benefit from lighter floor slabs that require smaller columns and foundations.
- Long-span floors — The reduced self-weight allows longer spans between supports without increasing slab thickness, giving architects greater design freedom.
- Sustainable building — Using up to 35% less concrete per slab translates directly into lower CO2 emissions and reduced raw material consumption.
- Renovation and extension — Where existing foundations have limited capacity, lighter Airdeck slabs may allow additional storeys without foundation reinforcement.
Advantages
- Weight reduction — Slab weight is reduced by up to 35% compared to a solid slab of equal strength.
- Material savings — Less concrete means lower material costs and fewer truck deliveries.
- Environmental benefit — Reduced cement consumption lowers the carbon footprint of the structure.
- Design flexibility — Longer spans and thinner structural elements open up architectural possibilities.
Related terms
- Biaxial voided slab
- Reinforced concrete slab
- Sustainable construction
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