Worthington Homes, Sydney
After trialling BIAX on a couple of smaller slabs, the builder used it on a 40-lot subdivision, completing 36 slabs in just over four weeks.[5]
Product research profile
BIAX Foundations
An Australian foundation system using recycled plastic void formers as an alternative to conventional expanded polystyrene waffle pods.
Its stackable, interlocking design seeks to improve material efficiency, transport, installation and construction waste outcomes. Here is what the evidence shows, and what it does not yet.
- Australia
- Foundations & Concrete
- Recycled materials
PlaceholderPhotograph to come. We publish only images we have permission to use.
Image to come. We publish only images we have permission to use.
Circular Abundance research assessment
Where the evidence stands
A short summary of this profile. It describes the state of the evidence and does not score or rank the product. Commercial maturity and evidence quality are separate: one describes the market, the other how much independent evidence supports the product. Both are defined on our evidence page.
- Commercial maturity
Emerging commercial solution
Sold through trade and retail channels and used by several Australian builders, with a registered, third-party verified EPD (2025). We found no published test reports or third-party product certification, and the performance and cost reports are from the manufacturer, its partners and the trade press.
- Evidence quality
Partly verified
One independent element: a registered, third-party verified EPD. It covers the environmental data for the void former only. No test reports or third-party product certificate were found, and structural, cost and comparison claims are the manufacturer's, its partners' or the trade press.
- Environmental documentation
A third-party verified EPD reports impacts per tonne of void former (436 kg CO₂e for the product stage) and 100% recycled polypropylene content.[1] It does not report impacts per slab or compare with polystyrene pods. Packaging is 59 kg per tonne, which is 5.9% of product mass, although the EPD gives the total as under 5%.[1]
- Manufacturing location
Void formers are made at a single site at Minto, NSW.[1] The recycled feedstock is described in the EPD as imported post-consumer polypropylene, while the manufacturer brochure describes post-industrial waste, up to 80% sourced offshore.[1][2]
- Independent technical evidence
None found beyond the EPD. Compliance with AS 2870 and peer-reviewed designs are manufacturer statements, and the reviewers are not named.[2] No test reports or product certificate were located.
- Whole-system economics
Pods cost more per unit than polystyrene, and the company says whole-slab cost is comparable.[3][2] No whole-slab cost or independent comparison has been published. One retailer lists primary pods at $17.61 inc GST.[4]
- End-of-life circularity
Pods are single-use and stay in the slab. The EPD's baseline is landfill; recycling is a modelled alternative that assumes the pods are separated from the slab, and that separation is not demonstrated.[1]
- Key advantages
- Stackable pods under 2.5 kg each, described as taking about one-seventh of the transport space of polystyrene (a company claim).[2][3]
- Recycled polypropylene content verified through an EPD.[1]
- Builders report faster installation and easier handling, without cutting.[5][6]
- Engineer-designed slabs using the maker's layout and finite-element software.[2]
- Outstanding research questions
- Which test reports, peer reviews or certificates support the AS 2870 compliance statement, and who reviewed the designs?
- How do slab-level embodied carbon, concrete and steel quantities compare with a polystyrene waffle slab on a comparable site?
- What is the whole-slab installed cost, by soil class, against polystyrene pods?
- Is the post-consumer or post-industrial description of the feedstock correct, and how much is imported?
- Can pods be separated from a demolished slab and recycled in practice?
Editorial perspective · Our interpretation
Potential
BIAX addresses a real material in a high-volume product: the pods that form residential slabs. A recycled, stackable pod with a verified EPD gives specifiers a documented starting point, and the transport and handling claims are plausible for a nested, light product. If independent slab-level data show reduced concrete and steel, the case becomes much stronger.
Limitations
The verified evidence describes the pod, not the slab or the comparison that matters. Compliance, cost and speed claims rest on the manufacturer and its partners, and the plastic remains in the building at end of life. Until independent testing and a like-for-like assessment exist, BIAX is best read as a documented, promising alternative rather than a proven improvement.
At a glance
Each row shows the class of source behind it, so claims can be weighed appropriately.
| Origin & manufacture | Australian-owned company; void formers made at Minto, NSW. Originally developed by Italian structural engineer Fabio Parodi.[1][3] | Third-party verified |
|---|---|---|
| Category | Foundations & Concrete · Recycled & Renewable Materials | Our note |
| Product type | Modular recycled polypropylene void former for waffle-style (ribbed, voided) residential slabs.[2][5] | Manufacturer |
| Material | 100% recycled polypropylene (EPD: post-consumer, imported feedstock; see Materials).[1] | Third-party verified |
| Main range | BIAX-145 (230 mm slab, step-downs) · BIAX-215 (300 mm slab, main pod) · BIAX-500 (585 mm slab) · Mini Pod / Adjustable · Keystone connector.[2] | Manufacturer |
| Rib centres | 750 mm (typical Australian waffle pods are described as 1200 mm).[2][3] | Manufacturer |
| Pod weight | Under 2.5 kg per pod; pods for a 180 m² home fit one single-axle trailer.[2][5] | Manufacturer |
| Design basis | Engineer-designed slab using the maker's AUTOPod layout and Wafflesuite finite-element software; design minimum concrete 20 MPa.[2] | Manufacturer |
| Environmental declaration | EPD-IES-0021002:001, valid 17 Jun 2025 to 16 Jun 2030.[1][7][8] | Third-party verified |
| Supply | Sold through trade and retail channels including Bunnings Trade and Bianco (SA).[5][4] | Commercial partner |
Overview
BIAX is an Australian foundation system that replaces conventional expanded polystyrene waffle pods with interlocking recycled plastic void formers. The slab is still a ribbed, voided concrete slab designed by an engineer; what changes is the material and shape of the pods that create the voids.[5][9]
Its stackable design is intended to improve material efficiency, transport, installation and construction waste outcomes. This profile separates what has been independently verified from what is reported by the manufacturer or the trade press, and records what we could not find.
Independently verified
Manufacturer-reported
Not yet found
- Published test reports or third-party product certification
- Like-for-like environmental comparison with polystyrene pods
- Independent, measured case studies
How the technology works
A BIAX slab is a reinforced concrete slab on the ground with a grid of voids. The pods sit on the prepared ground, reinforcement is placed, and concrete is poured over and between them, forming a thin top slab supported by a grid of ribs.[5]
What is different from a waffle pod
- Material and shape. Compact, tapered polypropylene pods with 2 mm walls replace bulky polystyrene blocks. The taper lets pods nest inside each other for transport and storage.[2][3]
- Closer ribs. Rib centres are 750 mm, set closer than the roughly 1200 mm of typical Australian waffle pods. The 750 mm dimension is reported to originate from a New Zealand seismic standard.[3]
- Connected grid. Keystone connectors lock pods together, which the maker says prevents movement during the pour. Corner holes and a 50 mm base rim allow connection and consistent spacing.[2][3]
- Built-in spacing. Engineered ridges are described as removing the need for bar chairs; a combined spacer, the Auschair, is also supplied.[2]
Materials and environmental impact
The void formers are made from 100% recycled polypropylene, a figure declared in the EPD and consistent with a supplier-declared 90–100% recycled plastic content in Sustainability Victoria's directory and with launch coverage describing 100% recycled polypropylene.[1][10][11] The EPD was produced by Lifecycles and independently verified before registration.[8][12] Packaging adds 59 kg per tonne of product (LLDPE wrap 10 kg, PE strap 0.49 kg, wooden pallet 49 kg), which is 5.9% of product mass (59 ÷ 1,000). The EPD lists the pallet as under 5% (49 kg is 4.9%) and also gives the total as under 5%; the total figure does not agree with its own masses, so this page uses the arithmetic.[1]
What the EPD reports
Third-party verified, ISO 14025 / EN 15804+A2. Declared unit: one tonne of void former, weighted average across the product list. Single manufacturing site, data period 1 Jan to 30 Nov 2024.[1]
| Indicator (per tonne of void former) | Result |
|---|---|
| Global warming potential, product stage (A1–A3) | 436 kg CO₂e |
| Global warming potential, construction waste (A5) | 84.2 kg CO₂e |
| Non-renewable primary energy, product stage | 38,000 MJ |
| Renewable primary energy, product stage | 2,060 MJ |
| Net fresh water use, product stage | 2.80 m³ |
| Non-hazardous waste disposed, product stage | 550 kg |
| End of life: landfill scenario (C4) / recycling scenario (C3) | 97.0 / 377 kg CO₂e |
Figures checked against the EPD document on 14 November 2026. Values are for the landfill baseline; the recycling alternative changes only C3 (377), C4 (0) and D (0).[1]
Reading these numbers carefully
- Per tonne, not per slab. The EPD does not state the impact of a finished slab. Slab-level results depend on the engineered design and the number of pods.[1]
- No like-for-like comparison yet. The EPD states that comparison with other EPDs is limited unless the rules, functional unit, boundaries and methods match.[1] We did not find an equivalent verified declaration for polystyrene pods.
- Where the plastic comes from. Three descriptions are in circulation and they are not identical. The EPD describes the recycled content as post-consumer polypropylene imported from Malaysia.[1] The manufacturer brochure refers to post-industrial polypropylene waste and says up to 80% is sourced offshore.[2] The supplier-declared figure in Sustainability Victoria's directory is 90–100% recycled plastic content.[10] Post-consumer and post-industrial feedstocks carry different environmental meanings, so the EPD, which is the verified document, is the better guide to what was assessed; the difference should be confirmed with the manufacturer.
- End of life. The pods are single-use and remain within the slab. The EPD's baseline assumes landfill, with recycling as an alternative scenario that assumes the pods are separated from the slab.[1] The manufacturer describes the pods as recyclable;[2] we found no evidence on how often this happens in practice.
- Polystyrene diversion. The company says broad adoption could remove about 25,000 tonnes of polystyrene from the building market each year. This is a company projection.[9]
Technical performance and compliance
| Item | Reported | Source type |
|---|---|---|
| Standards | Described as "fully compliant to AS 2870, Section 4" (the residential slabs and footings standard).[2] | Manufacturer |
| Design review | Designs said to be third-party peer reviewed by leading structural and geotechnical engineers (not named). Each slab is a bespoke engineered design using finite element analysis.[2] Residential engineering firm Intrax collaborated with Biax and recommends the system to its building clients.[3][13] | Manufacturer |
| Soil classes | BIAX-215 for soils up to H2; BIAX-500 intended for multi-storey buildings and lighter slabs on E-class (extremely reactive) soils.[2] A 2021 brochure describes the BIAX 500 system (formerly Armadillo) as suited to poor ground and buildings up to four storeys, and as used in Christchurch's post-earthquake recovery.[14] | Manufacturer |
| Concrete | Design minimum 20 MPa.[2] | Manufacturer |
| Thermal | Additional R1.10 (winter) over a conventional 300 mm slab on ground, when used with a reflective DPM.[2] | Manufacturer |
| Shrinkage cracking | Said to be eliminated when designed to the maker's recommendations. A builder reports minimal to no cracking in slabs poured so far.[2][6] | Manufacturer |
| Intellectual property | Patent application AU 2019900795, Void Former, filed 11 March 2019. Current patent status not verified.[15] | Directory / register |
What we could not verify. The compliance statements above come from the manufacturer. Trade-press coverage repeats the manufacturer's statement that the product meets engineering and Australian-standard requirements but gives no test data or certification details,[3] and we found no third-party product certificate or published structural test report. Any use should rely on a project engineer's design and certification.
Installation and construction requirements
Engineer designs the slab
The slab is designed by an engineer, who sets reinforcement and layout. Existing waffle-pod designs cannot simply be swapped: a BIAX slab must be designed by an engineer.[2][3][5]
Materials are scheduled and ordered
The maker's AUTOPod software produces a pod layout and bill of quantities. The builder then orders through a supplier such as Bunnings Trade.[2][5]
Pods are placed and connected
Pods are placed on the prepared ground and click together without cutting; Mini and Adjustable pods are used at edge beams and step-downs.[2][5]
Reinforcement and concrete
Steel reinforcement is placed, then concrete is pumped and screeded over the pods.[5]
PlaceholderPhotograph to come. We publish only images we have permission to use.
PlaceholderPhotograph to come. We publish only images we have permission to use.
Site and logistics notes
- Pods weigh under 2.5 kg each and stack; stacked, they are said to take about one-seventh of the transport space of polystyrene (a company claim).[2][3]
- One builder reports storing pods for 20 houses in the space one load of waffle pods would occupy.[5]
- The manufacturer says costs depend on a properly prepared site, and that pods can be stored outdoors while pallet-wrapped.[2]
- Installation instructions, numbered steps and tolerances are not given in the public brochure; obtain current instructions from the manufacturer.[2]
Costs and commercial considerations
No whole-slab cost has been published, and no independent cost comparison was found. The available information points in two directions.
- Unit price is higher. Plastic pods cost more per unit than polystyrene.[3]
- System cost is claimed to be comparable. The company says the whole-system cost is comparable because installation is faster, transport is easier, and less concrete and lower-grade reinforcement are needed. It also says a simple one-for-one material swap "doesn't work financially".[3] For H1 and H2 soils the brochure says the system is comparably priced or cheaper than polystyrene.[2]
- Labour. A Sydney builder says the builder buys the system and the concreter charges an install rate; a construction manager at another builder estimates saving an hour or two per install.[5][6]
Indicative retail prices
| Product (Bianco stock code) | Price inc GST |
|---|---|
| BIAX Pod Primary 750 × 750 × 215 mm (810160) | $17.61 |
| BIAX Pod Step-Down 750 × 750 × 145 mm (810162) | $16.72 |
| BIAX Mini Pod 400/215 mm (810167) | $15.55 |
| BIAX Mini Pod 400/145 mm (810165) | $15.29 |
| BIAX Keystone Connector 145 & 215 mm (810168) | $2.70 |
One retailer's listed prices, viewed 14 November 2026. Prices vary by supplier, region and volume; they are not slab costs.[4] No warranty terms appear in the public brochure.[2]
Case studies
The reports below are published by the manufacturer or the trade press and have not been independently verified. We have not found a measured, independently reviewed case study.
Vogue Homes, south-west Sydney
Reported to use BIAX on over 95% of its builds, citing install time, reduced excavation and concrete, and sustainability. No dollar figures are given.[6]
Final Finish Concreting
The owner reports more than 10,000 m² laid in nearly two years. A SE Queensland builder is also quoted on using the 300 mm low-profile design for H1 sites.[2]
Independent measured case study
As-built concrete and steel quantities, cost and embodied carbon compared with a polystyrene slab on a comparable site.
Limitations and trade-offs
Evidence is mostly self-reported
Performance, compliance and cost claims come mainly from the manufacturer and the trade press. Even the trade-press coverage we found relies largely on company and partner statements, without published test data.[3]
Engineering redesign is required
BIAX is not a drop-in replacement for polystyrene pods. Adoption depends on engineers, builders and concreters changing familiar practice.[2][3]
Plastic stays in the slab
The pods are single-use. Recycling at end of life is a modelled scenario, and the practicality of separating pods from a demolished slab is not demonstrated.[1][14]
Imported feedstock
The EPD reports imported recycled polypropylene, so the benefit for Australia's own plastic waste is not clear-cut.[1][2]
No like-for-like carbon comparison
The verified EPD reports impacts per tonne of pods, not per slab or against polystyrene, so a net saving is not yet demonstrated.[1]
Higher unit cost
Pods cost more per unit than polystyrene. Any saving depends on the whole-slab design and site conditions.[3]
Technical documentation and references
Superscript numbers in this profile refer to the sources below, listed in the order they are first cited. The label on each shows the class of source and how much weight it deserves.
Source classes used in this profile
- Independent third-party verification. Documents reviewed by an independent verifier or programme operator, such as a registered Environmental Product Declaration. Verification confirms the method and data, not that a product is better than an alternative, or a certificate issued by an accredited certification body (for example a CodeMark certificate).
- Manufacturer information. Websites, brochures, datasheets and media releases published by the manufacturer. Useful for specifications, but claims are the manufacturer's own.
- Commercial partners and distributors. Builders, suppliers, licensors and consultants with a commercial relationship to the product. Often first-hand, but not independent.
- Trade and editorial media. Magazines, news sites and directories that publish product coverage. Some of it is sponsored or supplied by the manufacturer; each entry says so where known.
- Retail pricing. Prices listed by retailers on a stated date. Indicative only; not installed or whole-system cost.
- Government and industry directories. Public registers and directories (for example recycled-content directories and patent records). Entries are often supplier-declared.
- Third-party verified Biax Foundations Pty Ltd, Environmental Product Declaration: Void former from Biax Foundations, EPD-IES-0021002:001 (published 17 Jun 2025, valid to 16 Jun 2030; EPD Australasia / EPD International). Verification scope. What verification covers: the life-cycle assessment data and method behind the declaration, checked against the programme rules (ISO 14025 and EN 15804). What it does not cover: structural, acoustic, thermal, fire or other technical performance; compliance with the National Construction Code; comparison with other products; or the manufacturer's wider marketing claims. Technical values reported inside an EPD are the manufacturer's declared figures. Open source 1 (opens in a new tab)
- Manufacturer Biax Foundations, Biax overview brochure (undated). Open source 2 (opens in a new tab)
- Trade / media Michelle Wheeler, New foundations, create digital (Engineers Australia), 30 Jan 2023. Open source 3 (opens in a new tab)
- Retail price Bianco Construction & Industrial Supplies, void formers category (retailer listing, viewed 14 Nov 2026). Viewed 14 November 2026. Open source 4 (opens in a new tab)
- Commercial partner Bunnings Trade, What is the Biax foundation system and how does it work? (undated). Published by a retailer that stocks the product. Open source 5 (opens in a new tab)
- Manufacturer Biax Foundations media release, Biax helps Vogue Homes stay ahead of the game, Australian Manufacturing, 29 Nov 2022. Manufacturer media release republished by a trade site. Open source 6 (opens in a new tab)
- Third-party verified EPD Australasia, listing for Void former from Biax Foundations (products covered by the EPD). Verification scope. What this confirms: registration, status and validity dates of the declaration. It does not add verification of the content or of product performance. Open source 7 (opens in a new tab)
- Third-party verified EPD International, library entry EPD-IES-0021002 (status, PCR and validity dates). Verification scope. What this confirms: registration, status and validity dates of the declaration. It does not add verification of the content or of product performance. Open source 8 (opens in a new tab)
- Trade / media Sustainable innovation will revolutionise the way dwellings are constructed, Build Australia, 26 Oct 2021 (interview with Jim Prior, Biax). Interview with the manufacturer's representative. Open source 9 (opens in a new tab)
- Directory / register Sustainability Victoria, Buy Recycled directory: Biax Foundations (supplier-declared recycled content). Recycled content in this directory is declared by the supplier. Open source 10 (opens in a new tab)
- Trade / media Building Connection, Holloway Group, Biax Foundations launch concrete void filler, 3 Mar 2021. Open source 11 (opens in a new tab)
- Commercial partner Lifecycles, Biax Foundations Void Former EPD (LCA practitioner case study). Lifecycles developed the EPD under commission, so it is a consultancy engaged by the manufacturer. Open source 12 (opens in a new tab)
- Commercial partner Intrax, Intrax Housing & Biax Foundations produce Next Generation Slabs, 25 Nov 2021 (modified 27 Oct 2025). Published by an engineering firm that collaborated with the manufacturer. Open source 13 (opens in a new tab)
- Manufacturer BIAX500 Brochure (2021), hosted by Cresco Group. Open source 14 (opens in a new tab)
- Directory / register University of Melbourne Find an Expert, patent record Void Former (AU 2019900795, filed 11 Mar 2019; current patent status not verified). Open source 15 (opens in a new tab)
Manufacturer
Biax Foundations
Void formers manufactured at Minto, NSW.[1][10] Contact details as published by the manufacturer:[2]
- 2–6 Huntsmore Road, Minto NSW 2566
- 1300 438 242 (1300 GETBIAX)
- [email protected]