ROSS Engineering was contracted to detail, manufacture, supply, and install a stay-in-place waffle deck former system covering an area of 40,000m². The waffle deck provides a lightweight yet high-strength structural slab, designed to support pedestrian, equipment, and vehicular loading.

The project was delivered to exacting client standards, with strict control over materials, finishes, and critical dimensions. Each individual waffle dome incorporated 25 moving parts, requiring multiple sub-assemblies prior to full modularisation

Our scope of works included:

  • Design and manufacture of multiple bespoke fabrication dies to produce 14 different pressed panel types
  • Global sourcing of materials and components across three continents
  • Bespoke manufacturing to maintain fabrication and installation deadlines
  • Total project tonnage of 5,680 tonnes, comprising 29,760 individual formers
  • Full modularisation into 2,352 prefabricated modules, each containing 12 domes
  • Module dimensions of 2.4m × 6.7m