The Hybrid Waffle Raft

 

Overview

On this particular project, Intrax Consulting Engineers was tasked with the structural slab design of a single storey dwelling on a site with a soil classification of “P” due to the recently removed group of trees and an underlying soil class of H2. While we have touched on the potentially adverse effects existing trees can have on residential dwellings due to drying and shrinkage of soils in previous projects, it is also vital, and perhaps even more problematic, to consider the design approach when removing trees from a site with respect to swelling of soil that causes heave.

At Intrax, our extensive and increasing database of projects provides us with the added benefit of being in a position to more accurately understand underlying foundation conditions and soil profiles. As a result, we can more appropriately make judgments relating to questions such as “does the refusal on rock in a soil report represent a rock base or arbitrary floaters?”

Although we had the presence of basaltic rocks for this project, our data on neighbouring sites allowed us to make the judgment that these were likely to be floaters. This meant that there was likely to be a large swelling effect occurring in the soil due to the removed trees. In turn, leading to the specific design of the Hybrid Waffle Raft.

Methodologies & Technologies

The first step once the problem was discovered was to inform the client of the abnormal moisture conditions onsite that would mean an unconventional and unique design. This allowed open discussion between Intrax and AHB about the options and solutions that we could develop. We explored many options including; tying in piles forced below the nominated level of influence, an upgraded waffle slab, or an upgraded raft slab. It was critical to understand that the solution would not only be governed by what was the most cost effective, but rather it would be a combination of that and other critical factors such as; the performance of the foundation system, the preferences of the client, the ease of construction and availability of materials, the potential problems that may arise and how they could be mitigated.

Communication was a key part of this process as it enabled us to find critical information such as the exact time of tree removal from the developer. Information such as this proved pivotal in our design as it meant some of the assumptions that would otherwise have been conservatively made could be eliminated. Open communication also allowed AHB to make cost estimations based on suggestions and help us arrive at a cost effective solution.

We decided that we would develop a footing system that incorporates the deep internal beams of a raft with the internal ribs and a foam void formers of a waffle. This above ground system with largely spaced beams combined the cost effective nature of a waffle slab with the deeper footings of a raft to create a stiff footing that would resist the imposed forces of soil swelling. The added benefit this provided for the client was that it would not be too different from constructing a waffle slab.

Once the suggestion of a hybrid waffle raft was out there it was then up to us at Intrax to determine via computations whether it could work. The design process involved assessing the differential mound movement and making complex calculations using the SLOG software. Via a series of trial and error calculations and a feedback model, we were able to innovate and design the best solution for this problematic site.

Closing Remarks

It is important to recognise that we live in a country with extensive regions of reactive clays and there is no one size fits all solution for slab design in Australia. In the past, we have specified other design solutions for sites with removed trees. These have included; upgraded waffle slabs including double waffle pod construction, upgraded raft slabs with deep footings and suspended polyvoid slabs on Katana Piles. With the Hybrid Waffle Raft slab, we now have another design option for problematic sites. We continue to innovate at Intrax and want our clients to rest assured that through open communication and our design methodologies we will arrive at a solution our clients will be satisfied with.

“Our clients and their preferences are an important part of the design process at Intrax. Via open communication, discovery of requirements, and innovation we were able to arrive at the most cost effective and practical solution. The Hybrid Waffle Raft was a challenging project to work on and the basis for further development for future use of this approach as a viable optimised solution for sites subject to excessive swelling” 

Jamal Khoder
Residential Engineer

Phillip Campbell

Chairman of the Board – Non-Executive Director and member of the risk committee

Phillip Campbell is the Non-Executive Chairman of the Board of the Intrax Consulting Group.

Phillip is an experienced company director with a demonstrated history of successful transformations of public and private organisations by focusing on the intrinsic value of the business, working behind the scenes to improve the effectiveness of management and building strong foundations for growth.

Graduating from Queensland University with a Bachelors’ degree in Electrical Engineering, Phillip has been CEO/MD of a number of public and private companies in the manufacturing and engineering services sectors.

He is a Graduate Member of the Australian Institute of Company Directors.

Phillip has an abiding belief that a stable and safe family home environment is critical for children to achieve a sound education and establish the foundations of a productive life. This is one of the reasons he joined Anchor Inc and is currently its Chairman.

Danny Borzillo

Executive Director

Danny Borzillo is an Executive Director.

Danny has a broad range of experience gained over 30 years of working in the construction and engineering consultancy industries.

Danny is the co-Founder of Intrax Consulting Engineers and was instrumental in the establishment of the Business in 2003. The early success of Intrax was mainly attributed to Danny’s innovation in the volume housing market and positioning Intrax to off its unique end to end service.

Danny Borzillo held the position of Managing Director of Intrax and then joint Managing Director together with Robert Borzillo until March 2011 when Barry Borzillo was appointed.

Prior to establishing and working at Intrax, Danny was involved in several small to mid-sized engineering consultancy businesses. His roles in these companies included Business Owner, Director and Senior Manager, providing consultancy design and construction advice and design services to the building industry.

Danny holds a Bachelor of Engineering (Civil) from Victoria University, is a Chartered Member of the Australian Institute of Engineers and is a Member of several industry technical bodies.

Barry Borzillo

CEO/MD

Barry Borzillo is the CEO/MD of the Intrax Consulting Group

Barry has a broad range of experience in the construction, telecommunications, professional services and government outsourcing industries.

Prior to his appointment in March 2011 as CEO/MD of Intrax, Barry held CEO roles for the ESH group, Tenix Solutions and Ericsson Australia/NZ. He spent nearly four years in the USA in senior roles with Ericsson Inc.

Barry began his career at Ericsson in 1987 as part of the Graduate program. He holds a Masters of Business Administration (Executive) from the Australian Graduate School of Management, a Bachelors’ degree with Distinction in Electrical/Electronic Engineering from Victoria University, is a Fellow of the Australian Institute of Engineers and is a Graduate of the Australian Institute of Company Directors.

Barry is passionate about improving educational outcomes in disadvantaged communities which is one of the reasons he joined the Ardoch Youth Foundation Board for ten years, the last five of which he was also the Chairperson.

Andrew Taylor

CFO & Company Secretary

Andrew has more than 30 years of diverse and progressive senior financial experience in professional services, manufacturing and government industries. He is a trusted and proactive business partner, has developed and led high-performance teams, been a member of executive teams and Boards, and driven organisation change with profitability, working capital and structure.

Prior to his appointment in April 2018 at Intrax, Andrew was regional CFO – Australia and NZ region at Aurecon. He spent 17 years at Aurecon leading the finance team, corporatising the business and driving operations across ANZ and Asia.

Andrew is CPA qualified and holds a Bachelor of Business – Accounting.

Andrew’s career highlights include: aligning and integrating 2 major businesses; the initiation, design and implementation of reporting and budgeting software globally; and development and leadership of a new Finance function for a growing company. Andrew enjoys team leadership, developing and mentoring others to reach their potential, and is passionate about maturing, evolving and improving companies and businesses.

Nigel Guo

Executive Director and CTO

Nigel is the Chief Technology Officer of Intrax.

Nigel joined Intrax in 2007 and rapidly rose through ranks with the business. Nigel completed a Bachelor of Structural and Civil engineer from University of Melbourne, and also earned a  Master of Business Administration from Melbourne Business School.

Nigel has had many roles at Intrax, from engineer, to running the residential engineering and quality departments before being promoted into general management roles.

He has played a key role in continuing process and system improvement at Intrax, developing most of the processes and procedures used in the housing departments today that have enabled Intrax to scale with quality, while consistently delivering to clients..

In his spare time Nigel likes sketching, playing bass guitar and soccer.

Robert Borzillo

Non-Executive Director, member of the risk committee

Robert Borzillo is a Non-Executive Director of the Intrax Consulting Group. Robert has over 40 years’ experience working as an engineer in various capacities within the Australian building Industry.

Robert was a co-founder of Intrax Consulting in 2003 with a vision to establish a dynamic end to end values driven engineering consultancy delivering services into the residential housing and building construction industries in Australia

Prior to the establishment of Intrax Consulting Robert was General Manager of Porta Moulding working within the Australian timber industry; in forestry, manufacture and distribution of timber products for the residential building and construction industries.

In his earlier days, Robert also worked as an engineer for Humes Concrete. Involved in the design, manufacture, supply, and installation of precast concrete components for large scale civil and building infrastructure. Robert spent time working in Sydney NSW, and Far North Queensland on many projects. Prior to that Robert spent time with the Country Roads Board in road design and planning of Victorian road infrastructure.

Robert earned a bachelor’s degree from Victoria University, BE Civil is a Certified Practicing Engineer CPE, is on the National Engineers Register. NER, and an accredited practicing engineer in most Australian states. Robert is also a graduate of the Australian Institute of Company Directors. GAICD.

Robert’s passion outside of work is travel and snow skiing. He has had the privilege to combine these passions traveling extensively and skiing in Australia, New Zealand, USA, Japan, Italy, and Switzerland.