Tuff Pods Void Form
Extremely strong EPS waffle pods for creating concrete slab floors
without traditional footings.
Lightweight Void Form Systems for Concrete Slabs
Building Product Information SheetEXPOL Tuff Pods are lightweight EPS non-structural void-formers, containing recycled material, that are used to create the internal ribs, thickenings and edge beams, and to support the concrete topping slab until it cures. The concrete ribs and topping slab provide the structural strength, and while the pods initially act as void-formers, they also offer insulation to the slab, adding thermal performance to the floor system.
What Are EXPOL Tuff Pods?
EXPOL Tuff Pods are lightweight EPS non-structural void-formers, containing recycled material, that are used to create the internal ribs, thickenings and edge beams, and to support the concrete topping slab until it cures. The concrete ribs and topping slab provide the structural strength, and while the pods initially act as void-formers, they also offer insulation to the slab, adding thermal performance to the floor system.
Advantages of Pod Systems
- Reduced concrete usage
- Improved construction efficiency
- Optimised structural performance
- Better project cost control
Applications & Performance
Suitable for residential and commercial pod floor / raft slab construction as set out in the engineer's design.
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. 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.
Key Features & Benefits
Construction Innovation
Construction Benefits
Eliminates strip footings, faster construction process, reduced excavation work, and lower labour costs.
Performance Features
High strength-to-weight ratio, excellent load distribution, thermal insulation properties, and long-term durability.
Applications
Perfect for residential foundations, commercial slabs, industrial flooring, and special construction projects.
Product Specifications
| Product Image | Length (mm) | Width (mm) | Thickness (mm) | |
|---|---|---|---|---|
| EXPOL Tuff Pods Moulded (Non-Structural) |  | 1100 | 1100 | 220 |
| 1100 | 1100 | 300 | ||
| Solid Pods made from Recycled Material - Non Structural |  | 1200 | 1200 | 200 |
| 1200 | 1200 | 300 | ||
| 1800 | 1200 | 200 |
System Components
100mm Spacer
300mm Spacer
PodStick
UNIMAX Spacer
Center Spacer
Clip-on Spacer
Tuff Pods Specifications & Sizes
EXPOL Tuff Pods are shape-moulded EPS waffle pods used to create 100mm concrete ribs in raft/floating slab systems, supplied with matching spacers and Podsticks.
| Specification | Detail |
|---|---|
| Material | Expanded polystyrene (EPS), shape-moulded with a waffle design |
| Function | Component used to create 100mm concrete ribs throughout the floor, providing additional strength and superior insulating qualities |
| Manufacturing standard | AS 1366 Part 3 1992 |
| Recycled content | Contains recycled content; offcuts can be recycled |
| 100mm Spacer | Only suitable for 220mm pods, used for internal ribs |
| 300mm Spacer | Only suitable for 220mm pods, used for slab edge beam and thickenings |
| UNIMAX Spacer | Sits on the ground between pods, suitable for use with any size Tuff Pod, clips together to form any size spacing required |
| PodStick | Used as an alternative to mesh/bar chairs, providing more support for steel mesh over polystyrene |
Sourced from the EXPOL Technical Guide (POD Floor Systems section) and Building Product Information Sheet above. For project-specific design, contact the EXPOL Tech Team.