16/08/2026
I believe that suspended waffle slabs were around before the waffle pod slab & footing system.
With waffle slabs, a reuseable void former, creates a grid of beams tapered in their depth, between which a thin slab spans. This waffle slab is contrasted against the alternative of a thick slab, and the formation of the voids save concrete.
With a waffle pod slab/footing system, the comparison is with a stiffened raft on ground. If lift the stiffened raft system out off the ground and place on top of the ground. Thr first thing to notice is that the beams can no longer vary in depth, they all have to extend down to the ground to provide support. Next the space between beams is no longer infilled with dirt, so a void former is required to create this void in the concrete casting, and otherwise support and form the sides of the beams.
So its an issue of designing and making a mould, pattern or die as may otherwise be referred to in casting and moudling of other materials. The telephone companies have narrow trenching machines for layering cables. Using such trenching machines narrow beams can be made in the ground. However, 110mm is only just wide enough for the human hand to fit, and only just wide enough for the vibrator/compacter used to consolidate the concrete. Deep narrow beams are not practical to install reinforcement into. Also the deeper that go into the ground the more unstable the side walls of the trenches, so shoring becomes necessary. The other issue is that the trenching machine or mechanical shovel has to have somewhere to sit, and be able to reach each of the trenches which have to be dug. The weight of the machinery can collapse the walls of the trenches.
So there are issues to be considered when designing and constructing the mould in the ground or above the ground. (though probably no design takes place) It is to be noted that large metal castings are cast in the ground, and a foundry floor is likely to be dirt, so that moulds can be cut/dug into the ground. So concrete is not unique in being cast in the ground.
Another point to note is that increasing spacing of beams typically doesn't save material. Beams at greater centres need to be bigger to carry more load. Members spanning between the beams have to be bigger to span greater distances. Spanning greater distances will typically add material, whilst changing spacing will typically just redistrubute the material in the members being spaced.
So if double spacing of beams, then double load on the beams, and therefore resistance needs to double. Whilst for the uniformy distributed loads we normally consider, doubling the span, results in a need for 4 times the resistance. So typically want to keep spans low, which means the spacing of supporting members needs to be kept low. A slab on ground is supported by the ground, the slab in a waffle pod system is suspended and spanning between beams. (barring complications of unstable or expansive soils).
Irrespective of maximum spacing permitted for beams, in the NCC/BCA and residential slab and footing code (AS2870), beams need to be under load bearing walls. So starting point is typically laying out beams under the perimeter of the building, and other load bearing walls. If walls don't form a simple rectangle and are stepping in and out, then beams start coming closer together. Then if wish to use waffle pod system, need to fit the grid to the floor plan and get its narrow beams where needed. There is also an issue as to whether these narrow beams have adequate weight to provide hold down againt wind uplift, or otherwise the system has adequate resistance to activate a large area of slab and beams to provide hold down without cracking (to failure).
For a given project need to assess whether 110mmwide beams at 1200mm centres or 300mm wide beams at 4000mm centres is preferable. Whether it is preferable to put the beams in ground, or above ground. Also assess the viability of the construction process.
It is not an automatic given, that the waffle pod system is a lower cost option.