CORDEK LTD

SPRING COPSE BUSINESS PARK
SLINFOLD
WEST SUSSEX RH13 0SZ

Tel: 01403 799600
Fax: 01403 791718

Company Logo

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

 

 

ACCESS RAMPS Disabled Access Ramps .See Also MOBILITY RAMPS:
ACCESS RAMPS Portable .
ACCESS RAMPS Temporary .
AIR BRICKS Ground Gas Ventilation .
BOARDS Antistatic .
BOARDS Crush Resistant .
BOARDS Flame Retardant Boards
BOARDS Polypropylene .
BOARDS Protection For Waterproofing Membranes
BOLLARDS Ground Gas Venting .
BUILDING PROTECTION Temporary Correx .
CAVITY TRAYS Gas Barrier .
COLUMN FORMERS
DAMPCOURSES Gas Resistant .
DAMPCOURSES Hydrocarbon Barrier .
DAMPCOURSES Methane Barrier .
DEBRIS CONTROL
EXPANDED Polystyrene EN 13163:2001
EXPANDED Polystyrene Loadbearing
FABRICATIONS EPS (Expanded Polystyrene)
FABRICATIONS EPS Loadbearing
FLOOR Protection Temporary Correx
FLOORS Concrete In-Situ Specialist Moulds
FLOORS Concrete In-Situ Trough Moulds
FLOORS Concrete In-Situ Waffle Moulds
FORMERS Expanded Polystyrene .
FORMERS Purpose Made .
FORMERS Staircase .
FORMWORK Accessories .
FORMWORK Concrete .
FORMWORK Curved .
FORMWORK Dished Floor .
FORMWORK Elements .
FORMWORK Insulating .
FORMWORK Insulating ICF Systems
FORMWORK Moulds .
FORMWORK Moulds Architectural
FORMWORK Moulds Archway
FORMWORK Moulds Bridge Parapets
FORMWORK Moulds Columns
FORMWORK Moulds Contoured Roofing Roofs
FORMWORK Moulds Diving Boards
FORMWORK Moulds EPS
FORMWORK Moulds Floor
FORMWORK Moulds Glassfibre Fibreglass Moulds
FORMWORK Moulds Helical Staircases
FORMWORK Moulds Internal
FORMWORK Moulds Light Recesses
FORMWORK Moulds Marine Applications
FORMWORK Moulds Polypropylene
FORMWORK Moulds Purpose Made Bespoke
FORMWORK Moulds Railway
FORMWORK Moulds Re-Usable
FORMWORK Moulds Spiral Staircases
FORMWORK Moulds Trough and Waffle
FORMWORK Moulds Vaulted Ceilings
FORMWORK Permanent .
FORMWORK Permanent Ground Beams
FORMWORK Permanent Ground Heave Protection
FORMWORK Permanent Ground Movement Protection
FORMWORK Permanent Pile Caps
FORMWORK Sloped Floor .
FORMWORK Specialist .
FORMWORK Systems .
FOUNDATION Clayheave Protection .
FOUNDATION Clayheave Protection AGREMENT CERTIFICATE HOLDERS
FOUNDATION Engineering .
FOUNDATION Gas Passive Venting Systems .
FOUNDATION Ground Heave Protection Boards / Sheets .
FOUNDATION Ground Heave Protection Boards / Sheets AGREMENT CERTIFICATE HOLDERS
FOUNDATION Ground Heave Protection Boards / Sheets Expanded Polystyrene EPS
FOUNDATION Ground Heave Protection Boards / Sheets NHBC Technical Standards
FOUNDATION Ground Heave Protection Boards / Sheets Pile Collars
FOUNDATION Ground Heave Protection Panels .
FOUNDATION Ground Heave Protection Panels AGREMENT CERTIFICATE HOLDERS
FOUNDATION Ground Heave Protection Panels Gas Venting
FOUNDATION Ground Heave Protection Panels NHBC Technical Standards
FOUNDATION Ground Heave Protection Panels Thermal Insulation Combined
FOUNDATION Ground Movement Protection .
FOUNDATION Ground Movement Protection AGREMENT CERTIFICATE HOLDERS
FOUNDATION Systems Shallow Depth Minimal Dig Insulating Expanded Polystyrene Pods EPS
GAS Protection Panels Methane Barriers Ground Soil Level
GAS Protection Systems .
GAS Ventilating Systems Passive Ground Gas Venting Media
GROUND BEAM Formwork .
GROUND MOVEMENT Protection .
IN-SITU CONCRETE Moulds .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS)
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Above Ground Wall .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Acoustic Wall .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Basement Wall .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Curved Wall .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Earth Sheltered Wall .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Swimming Pool Construction .
INSULATING CONCRETE FORMWORK (ICF SYSTEMS) Zero Energy Buildings .
JOINT SEALING STRIPS . .
LANDFILL Engineering .
LANDFILL Lining Barriers .
LANDFILL Site Construction .
LANDSCAPING Structures .
LANDSCAPING Structures EPS Purpose Made
LIFT SHAFT Construction Shuttering
MEMBRANES Acid Resistant EN 14030
MEMBRANES Alkali Resistant EN 14030
MEMBRANES Chemical Resistant .
MEMBRANES Chemical Resistant EN 14414
MEMBRANES Chemical Resistant EN 14415
MEMBRANES Damp Proofing DPM .
MEMBRANES Gas Barrier .
MEMBRANES Gas Barrier BS 8485:2015
MEMBRANES Gas Impervious .
MEMBRANES Gas Retardant .
MEMBRANES Gas Retardant Self-Adhesive
MEMBRANES Methane Gas Retardant Methane Barrier
MEMBRANES Radon Barrier .
MEMBRANES Radon Resistant .
MEMBRANES Self Adhesive .
MOBILITY RAMPS Lightweight Portable
PARK LANDSCAPING STRUCTURES .See Also LANDSCAPING: Structures .
PERMANENT Shuttering .
PILE Cap Formwork
PILE Locators .
PILING Accessories .
PILING Infill Sheet piling
POLYTHENE Sheeting .
POLYTHENE Sheeting Temporary
POOLS Ornamental EPS Construction
POOLS Purpose Made EPS Construction
PRIMERS: TYPES Bitumen .
PROTECTIVE Materials .
PROTECTIVE Materials Temporary
PROTECTIVE Sheeting Temporary
RADON Barriers .
RADON Protection Systems .
RADON Sumps .
RAFTS Floating EPS
RAILWAY PLATFORMS Temporary .
RAILWAY SHUTTERING .
RAILWAY TEMPLATE MOULDS
SHUTTERING Bridge Parapets .
SHUTTERING Columns .
SHUTTERING Elements .
SHUTTERING Elements Balconies / Balcony
SHUTTERING Lining .
SHUTTERING Permanent .
SHUTTERING Purpose Made Bespoke .
SHUTTERING Re-Usable .
SHUTTERING Sacrificial .
SHUTTERING Specialist .
SHUTTERING Spiral Staircases .
SHUTTERING Stop Ends .
SPACERS Polypropylene .
STAIR FORMERS .
STATION PLATFORMS Temporary .
STRUCTURAL WATERPROOFING Systems .
TANKING Systems .
TANKING Systems Waterproofing Membranes
TEMPLATES Arch Formers .
TEMPLATES Archway .
TEMPLATES Column construction .
TEMPLATES Dished Floor .
TEMPLATES Purpose Made .
TEMPLATES Sloped Floor .
TEMPLATES Special Moulds .
TEMPLATES Staircase Construction .
TEMPLATES Temporary .
THRUST BOXES
TROUGH Moulds .
TROUGH Moulds EPS
TROUGH Moulds Polypropylene
TROUGH Moulds Purpose Made
VENTILATION Cavity Wall (Natural) .
VENTING SYSTEMS Gas/Oil .
VOID FORMERS
VOID FORMERS EPS .
VOID FORMERS Purpose Made .
WAFFLE MOULDS Polypropelene .
WALKWAYS Temporary .
WALL COVERINGS PVC-u Sheet Temporary Protection .
WALL PROTECTION Temporary Correx .
WINDOW FORMERS EPS Purpose Made .
CELLCORE Foundation
CELLCORE HG Ground Heave Protection Panels
CELLCORE HX Ground Heave Protection Panels
CELLCORE HX Hexagonal Ground Movement Protection
CELLCORE PLUS Insulating Ground Heave Protection Panels
CELLFORM Permanent Formwork
CELLFORM HX Formwork with Ground Movement Protection
CELLVENT Gas Venting
CELLVENT HX Gas Venting Ground Heave Protection Panels
CORBREAK Pilehead Trimming
CORGRID Permanent Formwork Systems
CORREX Polypropylene Sheet
FILCOR Expanded Polystyrene
GROUNDFORM Permanent Formwork
HEAVEGUARD Ground Heave Protection Boards / Sheets
HEAVEGUARD Pile Collars
M MOULD Waffle Moulds
PILECOR Piling Accessories
POWERBASE Gas Membranes
PURAFLEX Gas Membranes
SEEKURE Temporary Protection Sheets
T FORM Trough Moulds
TIPFORM Landfill Engineering
TRI-GAS MEMBRANE Gas Membranes
TRIC TRAC Linear Building Spacers
VENTFORM Gas Venting

Cordek Supply - St Margarets Head Railway Tunnel

December 2019

The now disused St Margaret’s Head Tunnel was a structure originally formed as part of the Dunfermline to North Queensferry railway line, providing a link to the ferry service until the opening of the Forth Bridge in 1890 and remaining in limited use for freight until 1954. The vaulted roof and brick lined tunnel is located 15 metres below the A900 trunk road and the B981, adjacent to the northern approach to the Forth Road Bridge. Cordek were asked to supply a structural fill solution, encapsulated within a protective membrane to fill the entire cavity of the tunnel.

Project Scope

After thorough inspections of the tunnel were conducted, multiple signs of deterioration were detected. Two options were considered to make the tunnel safe; to continue to monitor and carry out localised repairs or to infill the entire tunnel void with a lightweight structural fill solution. Following an initial consultation, a formal technical proposal was delivered with full costings to Transport Scotland for approval. The decision was made to infill the tunnel with the cost-effective, lightweight infill material Filcor 20 Expanded Polystyrene (EPS) with a Flame Retardant (FR) additive. An additional benefit of this solution is that it would be reversible should the tunnel ever need to be re-commissioned at a later date.

The Solution

The 420.0 m long, 4.3 m wide and 5.1 m high tunnel had previously been sealed off at both ends and the adjacent cuttings filled in, with the only remaining access points via vertical shafts at each end. Due to the restricted opening of the access shafts, the Filcor 20 EPS was manufactured in 1200mm x 600mm x 500mm blocks to reduce wastage and allow for manual handling within the confined space. As the tunnel was previously used for rail and its location was under a trunk road, the precaution was taken to protect the Filcor 20 EPS blocks from any potential oil deposit build-ups and fuel spillages by using the Cordek VOC Membrane to line the tunnel prior to installation.

The Process

To ensure that the Filcor 20 EPS blocks were able to fit down the access shafts, a sample block was provided at the required dimensions to test the practicality of this method. Following successful trials proving that suitable access to the tunnel could be achieved, the tunnel was lined with the Cordek VOC Membrane that would encapsulate the Filcor 20 EPS blocks. Due to the vast void there was to be filled, the site received two articulated vehicle deliveries of Filcor 20 EPS blocks a day, three times a week to meet the installation programme for the project. Once offloaded at the surface, the Filcor 20 EPS blocks were lowered down the access shafts and onto a specially designed monorail system to travel the length of the tunnel. The blocks were built up gradually in stepped layers to allow for safe working at height. Once complete the access shafts were filled with concrete to seal the tunnel and prevent any potential damage to the Filcor 20 EPS blocks in the future.

Summary

Deliveries were made from December 2017 until March 2018 and in total 116no. articulated vehicles delivered 21,342 no. Filcor 20 EPS blocks to site. The use of large, articulated vehicles helped to reduce the impact on the surrounding neighbourhood, as it meant that the number of deliveries was reduced to a minimum. Ultimately, the project was delivered in full, on time and within budget with minimal disruption to the local roads networks, residents and businesses.

Cordek Supply - Folkestone Urban Sports Park

December 2019

A scheme designed by the award-winning Architects Guy Hollaway, The Urban Sports Park in Folkestone includes the world’s first multi-storey skatepark. The state-of-the-art facility is set on four levels and includes a skating area, climbing wall, new boxing club and café. Following the planned opening in late 2019, it is hoped that it will attract visitors from a wide radius across the South-East of England and beyond, providing an exciting and innovative opportunity for young people in the community.

Cordek were requested to design and supply a bespoke formwork solution to aid the construction of the integral, reinforced concrete slab soffit for the large skating bowls on the first floor.

Project Scope

The project Architects proposed a design that would provide both the durability and flexibility to modify and upgrade the facility as skating trends evolve. The concept was for the curved underside of the concrete skating bowls to be suspended above the underlying café space, allowing visitors to immerse themselves in the surroundings. A polished concrete finish was used for the skating surface with the external soffit clad in Glass Reinforced Gypsum (GRG) panels.

It was essential that the structural concrete layer of the skating bowls, sandwiched between the external surfaces, was dimensionally accurate and shaped precisely. Cordek provided a bespoke formwork solution to construct the basis of the skating bowl profile, suspended five meters above the ground floor.

The Solution

The complex shape and geometry of the skating bowls meant that a traditional formwork system would not be a suitable method of construction. The solution provided by Cordek involved the use of bespoke formwork units manufactured from Filcor Expanded Polystyrene which were accurately formed to the exact dimensions and profile required. Following confirmation that the formwork units had been accurately machined, an Epoxy Resin Seal Coat was applied to the casting surface to aid striking and provide the required finish to the concrete surface. As the formwork units had to be manually handled on site, the maximum size of each unit was determined by the permissible handling weight allowed.

The Process

The concrete frame sub-contractor Darby Groundworks Ltd provided the Cordek Project Design Team with Auto CAD drawings which were converted into a Solidworks format, so that a digital 3D model could be produced. Following approval of the 3D model, CAM data was then extracted allowing each individual formwork unit to be profiled using a CNC 5-axis router before an Epoxy Resin Seal Coat was applied.

An installation plan for the formwork solution was provided, indicating the location and positioning required to ensure the individual units fitted together by hand-assembly on site. The formers were located on three tier supporting timber decks, set at varying heights and integrated with the flat plywood floor formers to create seamless joints. Some of the formwork units were layered above others to create the desired shape, with dowelling rods used to secure them in place.

Once the formwork units were positioned, steel reinforcement was placed onto them, before sprayed concrete was applied over a four-day period to create the 500mm thick structural soffit slab. Finally, the formers were removed, and the upper surface of the reinforced concrete slab finished by polishing, with precast cladding panels secured to the underside.

Summary

In total 254 Filcor units were manufactured and supplied by Cordek, with 10 deliveries made over a six-week programme, in order to meet the contractor’s construction program and minimise the requirement for storage on site.

The challenge of suspending two large concrete bowls from the first-floor slab was ambitious, but the carefully crafted design has resulted in what is hoped to be the UK base for the next generation of extreme sports athletes.

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