CDI Innovative Construction Materials Ltd

The land owners of Seadune contacted us as they were having planning using regarding the foundation design on their new house that they were looking to build. The site in question was very close to the coast and they were effectively building on the beach. As such the planners required the building to have foundations that would allow the building to be dismantled and moved away from the sea in the event of major coastal erosion.As FastSlab is constructed using galvanised steel screw piles it is perfect to be used in coastal areas. Each section is also bolted together and as such can be unbolted. This allowed us to build into the design a way of unhooking all the elements and to be able to re-position them further away from the initial location should the need arise.Seadunes ground floor area of this project is 120m2 and the whole system was installed in just 5 days.

Lewis Deck was chosen, on this particular project in London, for a number of the key benefits the system brings. These being the strength of the system with only needing a thin concrete screed on top, the acoustic qualities & vibration control properties and the speed an ease of installation. This project even requested much longer sheets than standard in an effort to speed up the installation process. In fact you can see from the main photo above that some of the sheets were extremely long. The longest being just over 6.5m.This project was the installation of a new suspended, loadbearing concrete floor above an existing floor below. The space being used as a plant room for the hospital. The Lewis Deck was installed over a suspended steel grid of Light Gauge Steel C-section joists. A thin concrete was then installed over the top.This was a quick installation with the Lewis Deck being installed and then used as a safe working deck ahead of the screed being pumped in.

The project involved the conversion of the 1st floor of the Grade II listed Princes Building in Newcastle’s Quay side area into 10 apartments. The building, which was designed by William Parnel, who was responsible for some of the best architecture in the City, was built back in 1863 and as such posed some interesting problems when it came to bringing the building up to current standards. The introduction of the Lewis Dovetailed Metal Deck and screed system on top of the existing joists provided the necessary performance for airborne and impact sound and fire separation.

Built on a self-build development site at Graven Hill in Bicester, where every property is different, this house utilises a number of different design styles and is constructed from an ICF system called Durisol Blocks. The first floor is constructed using the Lewis Deck and includes sound separation, underfloor heating and wet-rooms. It is common for the 1st floor to see a liquid screed installed over the deck, however for this project the client just ordered a little additional of the concrete being poured down the walls to complete the floors.

The scheme includes infilling one third of Alexandra Dock with 780,000 m3 of material and reclaiming 7.5 ha of the river to create a new 650m quay wall, which can accommodate three offshore wind installation vessels.Construction will also involve dredging a new berth pocket, completion of earthworks and surfacing, building internal access roads and service networks, construction of a new Roll-on / Roll-off ramp and demolition of some existing buildings.Our Hody system was used in the 3 Primary Substations on the site to create the first floor decks of the steel framed buildings within the Alexandra Dock project.

The building was constructed using ICF blocks that are to have a rendered finish. Internally the ground floor is a concrete slab and the upper floor has timber posi-joists with the Lewis Deck and resilient strips laid above. 16mm underfloor heating pipes are then clipped into our new clip rail system with a free flowing screed then poured on top, 50mm thick. This then gives 20mm cover to the heating pipes, maximising the efficiency of the whole system.

It’s not everyday you get a phone call from an architect asking for help on a grade 2 listed mill building, but that is what happened to us back in April 2017 when Stephenson Studios contacted us with a problem they were having with floor to ceiling heights on their Brownsfield Mill project in Manchester.Their design criteria was for the existing 75mm thick timber mill boards to be retained and each of the apartments in the building would have these as an exposed ceiling. The idea was to keep the building as rustic and to retain as much of the original look and feel of the listed mill building as possible. Because of this all of the acoustic (Part E.) and fire Building Regs. (Part B.) requirements would have to be installed above the existing floor.The drawings we were sent through identified a floor build up, on top of the mill boards, at nearly 300mm thick. This started with a self levelling compound on top of the mill boards, to level them to, and then a timber on timber solution with a final layer of cement particle board prior to the oak flooring being installed.This thick floor section was causing a problem due to the original oak beams that were in place meaning the floor to ceiling heights weren’t as high as they needed to be. This design was compounded flowing the removal of the bitumen floor covering. When the mill boards were exposed and then levels were taken across each of the floors it was clear that the original design was no longer suitable for the project.With the age of the building some of the mill boards were beyond repair and each of the floors needed levelling up so the use of self levelling compound and a timber/ cement board solution also became a very expensive solution. We were asked if we could come up with a solution that was able to reduce costs and time and also to be able to achieve the required acoustic and fire requirements for this type of conversion project.Our initial thoughts on the project was to use timber ferrings, 100mm wide at 600mm centres, to lay our Lewis Deck system onto. This was reducing the number of ferrings by 50% (these were originally at 400mm centres) and it also removed 4 layers of timber/ cement board as well as the self levelling compound from the project. Following a meeting on site however, and after being able to fully talk to the design team and developer about what the Lewis Deck system can do we agreed that we would look at putting the ferring strips at 1400mm centres with the Lewis Deck being laid across at these centres. Rubber granulate acoustic strips would be installed on top of each of the timbers and mineral wool insulation would then be installed between. This would allow more material to be removed from the project but crucially still hit both the acoustic and fire requirements of the project.A test floor was commissioned, by the acoustic engineer, and built in August 2018 which passed all tests. You can see from the photos below the Lewis Deck laid at 1400mm centres for the middle section of the test with the 15mm thick rubber granulate acoustic strip laid on top of the timber ferrings. These timbers, due to the nature of the mill boards below, had to be installed individually to differing heights.The first full delivery of Lewis Deck arrived on site at the beginning of June 2019 following on from the steel strengthening works that were being carried out on site.The deck was quickly installed across the whole first floor in just a couple of days and the first screed pour was scheduled for the following week. The whole floor was poured using an anhydrite screed in just a few hours.The project continued on and the last main section of floor was poured on 19th December 2019, exactly 6 months after the first of the pours.This grade 2 listed mill building was a great project to work on. One that gave us a lot of challenges to overcome from the outset and one that helped overcome a number of issues that kept dropping up as the remedial works on the building progressed. We are delighted with the final result.Developer: Urban SplashFloor Installer: Trent Construction Services Ltd.

This new-build house was in a remote location and off-grid for mains gas, the house was to be heated by a heat pump and so efficiency was a major consideration for the project. The Lewis Deck system was chosen for the 1st floor of the building to provide the same efficiencies for the underfloor heating as the concrete ground floor as well as providing a high level of acoustic separation for this quality timber frame project. The build-up included the Lewis flanking and resilient strips, Lewis Deck, Anhydrite liquid screed and underfloor heating pipes.

We keep on being asked about how to lay our Lewis Deck system and the previous installation video wasn’t ideal when it came to showing how simple this was. So, in conjunction with the manufacturer of the deck we’ve had a series of new videos produced.

Initial project meetings first started in early 2008, the clients owned a small cottage on the site which had been extended several times during the 80’s and had permission to make further adaptations. The mixture of building standards meant that their home was extremely drafty and very energy inefficient. The site itself is particularly exposed. The design which achieved planning permission was a crescent form which steps and slides into the slopes on the site. The crescent formation is in direct response to solar orientation.The brief was to design a building which would accommodate the family for many years into the future, the planned occupancy would be for 5 adults. Additionally, the home will be used for large family occasions. A requirement was set for a minimum 16 seated spaces to be available for dining during these family occasions.Op-Deck was added into the scheme very early into the design process as the way of creating the highly insulated structural floor as the house was being designed under Passivhaus standards. The overall U-value of the property is 0.1w/m2K as standard. The system was installed on the lower and ground floors and also the roof.

Insworke Mill was originally built in 1590 and survived as a working Mill until the First World War. After falling into disrepair it’s now undergoing a major refurbishment to convert it to its new life as commercial properties to the ground floor with a luxury residential dwelling above. To the first floor a Lewis® Deck/screed solution was used to provide acoustic separating floors with timber beams left exposed, replicating the original beams. On the ground floor; Lewis® was used as part of a warm floor solution above the cellar areas. U/F heating was incorporated in all floors.

Providing 21 affordable homes in the first ‘carbon negative’ housing community of its kind in the UK. The initial concept began in 2009 with the aim of creating carbon negative housing. The project is ground breaking with a plan to lock away as much carbon as possible whilst generating excess energy from systems installed.Lewis Deck light weight steel/ screed composite floor system providing acoustic floors improving Building Regulations Part E standards by at least 8dB was installed in the apartments.This project achieved a Zero Carbon certification under the Code for Sustainable Homes and achieved Passiv Haus standards, but was not certified under this system. The performance was monitored by the Technology Strategy Board (TSB) as well as how the social tenants found the experience of living there given the lifestyle adjustments that were needed.The Lewis Deck was used as it achieved the enhanced acoustic and fire performance required in this project, especially given that this was a timber frame development. The elements of the building also had to achieve an A+ Green Guide to Specification rating from the BRE, this was achieved by using a liquid screed on top of the deck that contained a high recycled content.The project won a number of awards and was marketed as the UK's 1st "Carbon Negative" social housing scheme.

This self-build project was looking to improve the quality of the 1st floor construction, eliminate any danger of floor creaking that is common to timber floors and include an efficient underfloor heating solution.Underfloor heating work at its most efficient when it is installed within a screed, this is the way ground floor system are installed and being able to replicate this pipes in screed arrangement upstairs makes sense for the performance of the complete system.Also, by including some stiffened mass to the upper floors, the feel of the floor is replicated from the ground floor and also provides some very useful solar thermal buffering to keep summer temperatures under control in a building technique that otherwise has very little mass to to achieve this, especially on the upper levels.A timber frame structure requires the floor to provide racking to prevent the building from twisting. Meaning the floor needs to be secured to the joists below so the floor can stop twisting. There are 2 ways of installing Lewis Deck in timber frame structures. Firstly is to fix the Lewis Deck down or, alternatively, fix a timber deck on top of the timber joists and the Lewis is then laid loose on top of the timber with the resilient acoustic strips in between , thus, further enhancing the acoustic performance of the floor.

Max4 installation on refurb project.