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Forensic Engineering

The Inevitable Failure of Waffle Slabs

I took the time to read right through the Softley v Metricon Homes Pty Ltd decision, published by VCAT (the Victorian Civil and Administrative Tribunal) on 11 December 2014. Metricon was ordered to pay the cost of knocking down and rebuilding the Softleys’ house.

I was editing some of my waffle slab posts when it suddenly hit me: the slab movement in the Softleys’ home was a lot less than the slab heave and movement I have inspected and reported on in Queensland, including recently.

The VCAT Decision

For those interested, the full decision is here: Softley v Metricon Homes Pty Ltd.

If I were a builder of waffle slabs, I would be reading this decision very, very thoroughly.

It is also a good read for homeowners. It sets out the steps that matter in diagnosing slab heave and working out what caused it: measuring the movement, investigating the soil and moisture conditions, and tracing the movement back to its cause.

Say What?

Here’s the thing. The Softleys’ house had about 44 mm of uneven slab surface movement.

In contrast, in the Ipswich suburb of Bellbird Park I recorded slab surface unevenness in the order of 110 mm in a newish home.

So how is it that 44 mm of movement gets a house rebuilt, and 110 mm only gets an engineer’s investigation and report?

Part of the answer is that the amount of movement isn’t the only thing a tribunal looks at. The outcome of a building dispute depends on the cause of the movement, who was responsible for it, the contract, the legislation in that state, and whether a repair is actually practical. Each case turns on its own facts, and a tribunal decision in one state doesn’t automatically decide a case in another.

But it does show what is possible when movement is properly investigated and the cause is traced back to the way the house was built.

Waffle Slab Builders Should Be Nervous

I’d like to reiterate. If I were a builder of waffle slab homes, I would be very, very nervous.

Melton is a long way from Bellbird Park. But when homeowners in Brisbane, Sydney, Adelaide and Emerald (Central Queensland) discover that a tribunal has ordered a builder to demolish and rebuild a poorly performing house with a measly 44 mm of differential slab movement, I expect the tribunals and courts to get a lot busier.

Why Waffle Slabs Are So Vulnerable

Poor moisture control around a waffle slab house is probably inevitable. There are so many things that can go wrong:

  • movement leading to broken pipes, which then leak under the house;
  • porous backfill placed around the house;
  • slight subsidence of fill, tilting paths back towards the house;
  • overland flow, and gutters overflowing beside the slab; and
  • set-down patio areas that act as soakage trenches under the house.

Every one of these lets water reach the reactive clay under the slab unevenly, and that is what drives slab heave. I go through why waffle slabs are particularly exposed in beware waffle slabs, waffle slabs on H2 class soil and water around a waffle slab.

The Floodgates Have Opened

Just remember where you were when you found out that the cracks in your house could be enough for a claim against the builder to end with the builder rebuilding your home.

I’m not ambulance chasing. The ambulance has already left.

You didn’t hear it from me.

Matt Cornell
Cornell Engineers

Is Your Waffle Slab House Moving?

Whether a claim is worth pursuing starts with good evidence: how much the house has moved, why, and whether the cause traces back to the design or construction. Cornell Engineers investigates slab heave and cracking in waffle slab and raft slab houses, and prepares independent expert reports for disputes, including in QCAT. See our forensic structural engineering page for more.

Send us the property address, photographs of the cracking and of the ground around the house, a short description of what has happened, and any soil reports, engineering drawings or previous reports. We will review the information and let you know whether the matter is a good fit for Cornell Engineers before preparing a fee proposal.

Request a quote

This article is general commentary on a published tribunal decision and is not legal advice. If you are considering a claim against a builder, speak to a lawyer about your circumstances.

12 replies on “The Inevitable Failure of Waffle Slabs”

Hi Matt,
Since coming across some issues with the Waffle Pod Slab recently (horse has bolted) poured on my block, I informed the builder that my site was classed as a H2 (highly reactive clay) as per their Geotech report and they have cut into the clay level on the high side and there is evidence of top and subsurface runoff after heaver rain. They engineered the slab with a doubtful 85mm top slab being presumably a H1 class and not 100mm H2 class construction. I suggested that maybe the slab should have been the Hybrid WPS (Raft edge beams trenched below ground level) for improved stiffening. and I am awaiting their response. To alleviate their problem I have also suggested that not only are they having 3 pits and grates positioned on the high side for surface runoff (part of their engineering plan)but at their expense they should put Agi slotted piping and aggregate for subsurface runoff, parallel to slab and tapped into stormwater downstream of this slab with fall to at least comply with the so-called Warranty clause that the builder should provide an adequate initial diversion to comply with their guarantee signoff and the owner is responsible for diverting stormwater (retaining walls with Agi piping) after the build, preventing ingress under the WPS and subsequent heaving and shrinking. Very disillusioned Matt.

Hi David
We hear this all too often and very often after the proverbial horse has bolted.
I guess that’s why I have created my Youtube videos on drainage and sloping blocks and waffle slabs – to try and get in front of the issue. Sadly many of the suggested fixes are beyond the scope of a homeowner to implement themselves – but maybe they can be used to force the builder’s hand in the resolution of the problems.
I wish you well in your attempts to get what you deserve – a performing, trouble-free house. Homeowners shouldn’t be left to solve these problems on their own.
Best Regards
Matt Cornell

Hi Matt, i’m not 100% sure but i think the differential movement was 71mm mate in this case as stated in section 28 wasn’t it?

Matt, I am very interested in knowing would the Softley’s house have performed any better if it was a regular raft slab as opposed to the Waffle Pod design??
From my experience Waffle pods if designed according to AS2870 perform equally or better than standard rafts??
your view on this.. thanks.

I have seen Pier and beam slabs fail on the Darling Downs. I have build only around a dozen or so homes using WP slabs with no problems. Done a further 50 odd slabs for other builders and only a few did have movement Mostly caused by not building the site up prior of preparing the slab and engineers so called soil tests.
I was doing these slabs since the late 80,s and was one of the first concretors in Qld using this system. I had and old guy walk past my site once and he told me he used this system over 50 years back, only using bails of straw and besser blocks between the bails.

Matt,

I have attended a seminar conducted by FFSV in Victoria. Based on their findings especially in the west side of Melbourne that the soil can change from a class H to a P or E during change of season. In addition, I have also, been informally informed that a waffle slab can only span a max of 7m in both directions.. I believe what we need is to get all our engineering brains together and come up with a better solution to this matter. I also believe that we need to set up an organisation that will focus and provide proper training in assessing crack failure. I read in England that they actually have one and there are books published to properly diagnose a crack and provide proper solution.

J

Hi Jonathon
In Queensland, QBCC panel engineers get a fair bit of guidance on report structure and investigation procedures for house cracking / subsidence claims. We also have some wonderful engineers on the AS2870 committee that love to share their knowledge.
That same level of in-house experience is probably available in each state, but engineers are a funny bunch and aren’t always open to sharing their knowledge. So years of knowledge and experience can be lost when an engineer retires or moves on.
I’m sure engineers in each state could learn from each other and from overseas engineers (eg Texas has reactive clays). More open sharing would definitely advantage consumers.
Then we just have to teach consumers to stop searching out and taking the lowest price for footings.
All the best
Matt Cornell

I am very well aware of FFSV Domenic Lopes since knowing him for best part of nearly 8 years he has tought me a lot regarding soil testing and soil swell and shrink.
I respect his work and him as a person.
As to the Softley case you will find it was much more then 44mm it’s around 77mm if am not mistaken but I’ll read the case again.
I have 86mm movement my waffle pod slab has snapped in half 2020 builder try to install AG pipe around 3 sides if the house o my to fail the trenches are flowing backwards water flowing back under the slab now I have effoflorence coming through the the slab.

Hi Charlie
Thanks for your comment. I agree. The risk is just too high. Which isn’t to say raft slabs have never failed – just that sometimes bigger really is better.
Matt Cornell

Wow. Sure glad I haven’t done any waffle pods. Won’t ever be doing them either. Give me the full depth large footings full of reo.

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