B&K SYSTEMS/Total Floor Solutions says it’s developed a new solution to provide an ultra-lightweight flooring solution which it says has been successfully installed in the Battersea Power Station redevelopment project.
The system comprises energystore TLA insulation and Cemfloor Screed topping.
B&K Systems/Total Floor Solutions is a supplier of specialist floor systems to the construction industry providing what it describes as high performance products/systems to address specific on site logistic, handling and installation issues.
Cemfloor and energystore TLA
Cemfloor is described by the company as a cementitious self-levelling flowing screed flooring system comprising cement, fine aggregate, proprietary Cemfloor Binder, high-range water reducer, and water.
‘Cemfloor is produced in quality control approved and operated plants and delivered to site via mixer trucks, it’s a plant mixed product. Cemfloor is installed by approved contractors, who’ve been trained to lay Cemfloor flowing screed.’
The company continues: ‘Cemfloor screed can be installed as bonded, unbonded or floating screeds. It’s also suitable for use with underfloor heating. Cemfloor screeds are produced in accordance with EN BS EN 13813:2002 and have BBA Building Agrément Certificates.
‘Energystore TLA is a unique thermal lightweight aggregate combining EPS beads with Edilteco’s Politerm Blu technology. Politerm Blu technology is used in more than 40 countries worldwide to create innovative and unrivalled lightweight solutions.’
Says the company: ‘The combination of TLA and cement creates a lightweight product that has exceptional weight, thermal and acoustic properties. This makes energystore TLA the ideal solution for many applications.’
B&K Systems/Total Floor Solutions have used energystore TLA and Cemfloor Screed together on numerous projects. Mostly Cemfloor Screed is installed onto a separating membrane which has been placed on top of the energystore TLA insulation.
Since Cemfloor Screed and energystore TLA insulation are cement-based products, they can also be installed as a bonded system to allow for further weight reductions.
Battersea Power Station
Battersea Power Station is at the forefront of one of central London’s largest new developments. The £9bn project will see the creation of a vibrant new destination for London, housing a community of homes, shops, cafes, offices, leisure and cultural venues, with more than 19 acres of public space.
At the heart of the 42-acre development lies the Grade II listed iconic power station building which is part of Phase 2 of the re-development.
As part of the re-development of the power station building a lightweight floor build-up was required.
‘An ultra-light weight solution’
B&K Systems/Total Floor Solutions had a remit to provide a lightweight floor build-up and based on previous experience of using energystore TLA and Cemfloor screed they designed and proposed a new ultra-light weight solution for this project.
The proposal was for energystore TLA to be installed at various thicknesses to level out the existing uneven substrate with 30mm depth of Cemfloor CT C30 F6 screed then bonded directly onto the energystore TLA. According to the company, this system had the following benefits of the original specification:
B&K SYSTEMS/Total Floor Solutions says it’s developed a new solution to provide an ultra-lightweight flooring solution which it says has been successfully installed in the Battersea Power Station redevelopment project.
The system comprises energystore TLA insulation and Cemfloor Screed topping.
B&K Systems/Total Floor Solutions is a supplier of specialist floor systems to the construction industry providing what it describes as high performance products/systems to address specific on site logistic, handling and installation issues.
Cemfloor and energystore TLA
Cemfloor is described by the company as a cementitious self-levelling flowing screed flooring system comprising cement, fine aggregate, proprietary Cemfloor Binder, high-range water reducer, and water.
‘Cemfloor is produced in quality control approved and operated plants and delivered to site via mixer trucks, it’s a plant mixed product. Cemfloor is installed by approved contractors, who’ve been trained to lay Cemfloor flowing screed.’
The company continues: ‘Cemfloor screed can be installed as bonded, unbonded or floating screeds. It’s also suitable for use with underfloor heating. Cemfloor screeds are produced in accordance with EN BS EN 13813:2002 and have BBA Building Agrément Certificates.
‘Energystore TLA is a unique thermal lightweight aggregate combining EPS beads with Edilteco’s Politerm Blu technology. Politerm Blu technology is used in more than 40 countries worldwide to create innovative and unrivalled lightweight solutions.’
Says the company: ‘The combination of TLA and cement creates a lightweight product that has exceptional weight, thermal and acoustic properties. This makes energystore TLA the ideal solution for many applications.’
B&K Systems/Total Floor Solutions have used energystore TLA and Cemfloor Screed together on numerous projects. Mostly Cemfloor Screed is installed onto a separating membrane which has been placed on top of the energystore TLA insulation.
Since Cemfloor Screed and energystore TLA insulation are cement-based products, they can also be installed as a bonded system to allow for further weight reductions.
Battersea Power Station
Battersea Power Station is at the forefront of one of central London’s largest new developments. The £9bn project will see the creation of a vibrant new destination for London, housing a community of homes, shops, cafes, offices, leisure and cultural venues, with more than 19 acres of public space.
At the heart of the 42-acre development lies the Grade II listed iconic power station building which is part of Phase 2 of the re-development.
As part of the re-development of the power station building a lightweight floor build-up was required.
‘An ultra-light weight solution’
B&K Systems/Total Floor Solutions had a remit to provide a lightweight floor build-up and based on previous experience of using energystore TLA and Cemfloor screed they designed and proposed a new ultra-light weight solution for this project.
The proposal was for energystore TLA to be installed at various thicknesses to level out the existing uneven substrate with 30mm depth of Cemfloor CT C30 F6 screed then bonded directly onto the energystore TLA. According to the company, this system had the following benefits of the original specification:
- Significant weight reduction: the original specification had a weight of 300kg/sq m whereas the energystore TLA and Cemfloor proposal had a weight of 120kg/sq m
- Greatly reduced installation time: the original specification was a semi-dry system which would have been manually placed and compacted. Both energystore TLA and Cemfloor are flowable systems which are pumped into place and tamped to provide a smooth level surface
- Reduced cement content of energystore TLA and Cemfloor system leading to a lower CO2 footprint
- Faster turnaround time allowing follow on trades to progress with works without delays
- Lower curing time of the new system allowed the floor to be loaded with MEWPS faster
- Significant cost savings were also achieved.
Delivery of the system
The energystore TLA insulation was produced onsite by B&K Systems/Total Floor Solutions using a specially designed volumetric mixing truck product which batched the product using accurate, calibrated software; batching 0.5m3 every few minutes.
This method achieved an installation capacity of 15m3/hour. The energystore TLA insulation was pumped into place and finished to the required level using a tamping bar. energystore TLA insulation was allowed cure for 48 hours before being topped with Cemfloor Screed.
The Cemfloor CT C30 F6 screed was produced and delivered by Capital Concrete from its Silvertown location. The screed was produced in accordance with EN BS EN 13813:2002. The flow rate of every load was tested to ensure the product had the correct workability before being delivered to site.
The screed was installed by B&K Systems/Total Floor Solutions onsite team which bonded the screed directly onto the TLA insulation at a minimum depth of 30mm. An installation rate of up to 1,000sq m per day was easily achieved.
Since the screed was delivered to site, it eliminated the need to store materials onsite and reduced site congestion significantly. The surface regularity of the finished screed easily achieved SR2 tolerance. Following the installation of the screed topping the floor could reportedly be loaded with the following after the curing times shown: - Light foot traffic = 24-48 hours
- Erection of access towers/scaffolding = 7 days
- Full loading including MEWPS = 21 days.
Performance of the system
Following the installation of the system in-situ crushing resistance testing (ISCR) was carried out throughout the floor area with each test reportedly easily meeting the CAT A requirements.
Says the company: ‘The system was delivered ahead of schedule and a significant time saving was achieved compared to the original specified floor build-up. The floor will be covered with various types of flooring all of which are compatible with the Cemfloor Screed topping.’
Adds the company: ‘A special mention must be given to B&K Systems/Total Floor Solutions for developing and proposing this solution to the main contractor and architect for this landmark project and for their exemplary co-ordination and delivery of the system onsite.’
It concludes: ‘Also, too Capital Concrete for ensuring the Cemfloor Screed was produced as per the relevant quality standards and delivered to the site in a timely and efficient manner.’
www.cemfloor.co.uk
