EXPOL Tuff Pods for Pod Floor Insulation

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EXPOL Tuff Pods are extremely strong expanded polystyrene (EPS) pods that provide strength and high performance insulation in concrete foundations.

Up to 10% of a building's heat is lost through an uninsulated slab.  Expanded polystyrene insulation provides excellent thermal protection, helping to create a warm, dry and healthy indoor space.

Suitable for all raft or floating pod floor systems used in New Zealand, EXPOL Tuff Pods reduce preparation work, construction time and concrete needed for foundations.

 

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IDEAL USES

Pod Floors

EXPOL Tuff Pods are a component of pod floor systems. Used to create 100mm concrete ribs throughout concrete floors, EXPOL Tuff Pods are shape-moulded and incorporate a waffle design. EXPOL Tuff Pods are an ideal choice when compressive strength and resistance to water is required.

MORE ABOUT EXPOL TUFF PODS

Made from environmentally safe expanded polystyrene (EPS), EXPOL Tuff Pods help reduce the energy consumption of a building by protecting the concrete floor from heat loss.

EXPOL Tuff Pods are available in a range of sizes and are suitable for raft or floating floor slab systems. EXPOL supplies the full range of components required for the construction of a pod floor system, including spacers to hold the voids in place.

Using EXPOL Tuff Pods significantly reduces slab construction time. This insulation method is suitable for barrowed or pumped concrete. 

EXPOL Tuff Pods are 100% recyclable, and clean waste can be sent back to EXPOL for recycling at its in-house plant.

An inert product, EPS does not degrade over time. Thermal insulation performance and compressive strength is ensured for the life of the building. 

SYSTEM COMPONENTS

EXPOL supplies a range of components required for pod floor installation including spacers to align the Tuff Pods, and bar chairs for mesh support.  

EXPOL Pod Stick

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Used as an alternative to Mesh / Bar Chairs. Provides more support for steel mesh over polystyrene - read more.

EXPOL UNIMAX SPACERS

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The spacer sits on the ground between the pods and is suitable for use with any size Tuff Pod.  The spacer cleverly clips together to form any size spacing required.  EXPOL Unimax spacers can be used in conjunction with any other spacer type.

How much do I need

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EXPOL 100mm SPACER

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The spacer hangs between the pods to hold them in place while the concrete is poured.  EXPOL 100mm Spacer is used in conjunction with the 300mm spacer and the 220mm EXPOL Tuff Pod.

How much do I need

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EXPOL 300mm SPACER

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The spacer is used around the perimeter of a pod floor and spaces the pod 300mm away from timber boxing.  EXPOL 300mm Spacer is used in conjunction with the 100mm spacer and the 220mm Tuff Pod.

How much do I need

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MESH/BAR CHAIRS 25/40

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Use EXPOL Bar Chairs to hold the mesh either 25mm or 40mm above the Tuff Pods. EXPOL Bar Chairs have a large base so they will not squash the polystyrene pod.

WILTON JOUBERT SPACERS

EXPOL supply Wilton Joubert spacers on request.  They use two spacers that clip together to do the same job as the EXPOL Unimax

HOW MUCH DO I NEED?

CHOOSING THE RIGHT PRODUCT

To suit the many different pod floor systems, EXPOL supplies a variety of sizes to suit the specific design.

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CALCULATING HOW MUCH PRODUCT YOU NEED

To calculate the number of spacers required, use our calculator.

EXPOL Unimax SPACER

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EXPOL 100mm SPACER

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Note: It is important to refer to your engineers report/schedule. This information is a guideline only.

 

EXPOL 300mm SPACER

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Note: It is important to refer to your engineers report/schedule. This information is a guideline only.

 

Wilton Joubert

WJ 100 & 101 - Raft Spacer System - click to download information

 

INSTALLATION INSTRUCTIONS

STAGE 1

Clear and level the site.  Outline a footprint of the building site and spread a layer of fines over the area. Construct and erect the boxing and lay the damp proof membrane over the fines. Plumbing and services go in at this stage.

STAGE 2

The site is now ready for the placement of EXPOL polystyrene Tuff Pods, in conjunction with the EXPOL Unimax spacer, the Wilton Joubert spacer or the EXPOL 100mm and 300mm spacers. The most suitable spacer is generally determined by the engineer or specifier. Pods are placed 300mm in from the perimeter boxing and 100mm apart over the floor area (or as recommended in the engineer's schedule). Reinforcing steel is laid around the perimeter and between the pods. Steel mesh is then laid over the pods using bar chairs where necessary.

STAGE 3

The site is now ready for the pouring of concrete, which can be pumped or barrowed. The concrete should be vibrated and screeded, as per normal practice, and adequate curing time should be allowed. Remove the boxing after curing.

Technical information

Standard POD construction details

Masonry Wall

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Timber Frame

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Brick Veneer

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300mm Rib

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100mm Rib

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FREQUENTLY ASKED QUESTIONS

How strong are EXPOL Tuff Pods?

EXPOL Tuff Pods are constructed from expanded polystyrene (EPS), a material that is 98% trapped air. The cellular structure of the polystyrene foam keeps the pods dimensionally stable for the life of the building. Polystyrene insulation board is also resistant to moisture and rot.

Do EXPOL Tuff Pods come in different sizes?

Yes. EXPOL Tuff Pods come in a range of sizes to suit the many types of pod floor systems on the market.

How do the EXPOL Tuff Pods stay in place?

Use EXPOL spacers or Wilton Joubert spacers to hold the polystyrene pods in place during concrete pouring.  

How do EXPOL Tuff Pods improve thermal performance of a building?

An inert, rigid foam product, EPS holds its shape and does not deteriorate with age.  EXPOL Tuff Pods do not settle over time, ensuring the R-value for the life of the building.

Are EXPOL Tuff Pods water resistant?

EXPOL Tuff Pods are virtually unaffected by water, performing better than other foamed plastic products on the market.  Tests on EPS board retrieved after 30 years underground showed less than 1% water content.  Tests taken on EPS board periodically submerged over the same period of time showed less than 4% water content.  

Do EXPOL Tuff Pods give off toxic fumes?

In the event of a fire, the level of toxicity of EPS is no greater than timber.  EPS does not off-gas hydrogen cyanide or hydrogen chloride.  No CFCs or HCFCs are used in the manufacture of EXPOL Platinum Board.

WHERE TO BUY

EXPOL products are available at a number of leading building products stores. Find your nearest stockist here.

View Expol Distributors in a larger map

Fast Facts
  • EXPOL Tuff Pods are suitable for any raft or floating pod floor system used throughout New Zealand.
  • Made from expanded polystyrene insulation boards, EXPOL Tuff Pods are exceptionally durable, retaining compressive strength, resistance to water and thermal insulation for the life of the building.
  • Use EXPOL Tuff Pods for a solid insulation solution that achieves a substantially higher R-value than other insulating materials.
  • Expanded polystyrene has a long established reputation for creating energy efficient homes that rely less on heating and cooling.
  • Made of 98% air, EXPOL Tuff Pods are exceptionally “tuff” and do not settle over time.
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General
Enquiry Form

General Enquiry

Tel: +64 (9) 634 3449

Free Phone: 0800 86 33 73

sales@expol.co.nz

105 Captain Springs Rd., Onehunga, Auckland

Tel: +64 (9) 634 3449

Free Phone: 0800 86 33 73

sales@expol.co.nz

105 Captain Springs Rd., Onehunga, Auckland

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