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Last edited 13 Nov 2017
Beam and Polystyrene Block Suspended Flooring - Case Study
- Project: Residential New Build Housing
- Location: North Yorkshire
- Sector: Flooring
- System: Stylite T-Beam Infill Insulation
- Size: 323 Plots / 12,000m2
House builders face many problems during the construction of new homes, and are currently seeing a shortage of concrete blocks. The shortage is caused by a reduction in the availability of fresh Pulverised Fuel Ash (PFA), which is an essential ingredient of concrete blocks. Demand has been outstripping supply and as a result the cost of blocks has also risen sharply.
To avoid any supply problems or costly on-site delays a national house builder wanted an alternative product to the traditional beam and concrete block floor for a development consisting of more than 300 houses in North Yorkshire. The client also wanted to achieve Part L Building Regulations for thermal performance and demonstrate an overall cost saving.
 Design Solution
The unique Stylite T-Beam Suspended Floor Insulation was introduced to the client's design team, who quickly saw the benefits it offered and were keen to specify the system. SPI worked closely with the client and concrete beam manufacturer to design a holistic solution.
The Stylite T-Beam system comprises lightweight Expanded Polystyrene (EPS) panels contour cut to suit the profile of the concrete beams. The interlocking EPS panels are installed between the beams with the “toe” extending underneath to provide the all round insulation and eliminating cold bridging.
The panels specified were 230mm deep EPS70 to achieve a U-value of 0.22 W/m2K meeting the clients requirements for Building Regulations. To complete the floor design a macro fibre concrete screed topping of 75mm was specified.
- Quick and reliable deliveries.
- Excellent thermal performance.
- Interlocking panels prevent cold bridging.
- Lightweight blocks reduce health and safety concerns on site.
- Fast installation reduces labour costs.
The Stylite T-Beam is up to 25% faster to install compared to a traditional beam and concrete block floor. The infills are designed to ease the installation process and therefore reduce labour time and costs.
The site manager commented “We can complete a whole floor much quicker using T-Beam infills compared to using concrete blocks, and they are so light to carry.” “The lads can cut the polystyrene easily to fit around service pipes and the floor screed can go straight over the top without having to lay an insulation top sheet.”
 Related articles on Designing Buildings Wiki
- Beam and Infill Suspended Floors.
- Cavity wall insulation
- Celotex RS5000 PIR insulation.
- Conventions for U-value calculations (2006 edition) BR 443.
- Designing out unintended consequences when applying solid wall insulation FB 79.
- EPS Geofill Civil Engineering - Case Study.
- Insulation for ground floors.
- Passivehaus Foundation Insulation - Case Study.
- Polyurethane spray foam in structurally insulated panels and composite structures.
- Profiled and cut to fall roof insulation - case study.
- Solid wall insulation.
- Sound insulation.
- Transparent insulation.
--Styrene Packaging and Insulation Ltd 09:45, 13 Nov 2017 (BST)
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