SPANTHERM: THE INSULATED PRECAST CONCRETE GROUND FLOOR SYSTEM FROM CREAGH. www. Spantherm.com REV. E JULY 2013

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1 www. Spantherm.com REV. E JULY 2013 SPANTHERM: THE INSULATED PRECAST CONCRETE GROUND FLOOR SYSTEM FROM CREAGH

2 Contents The Insulated Concrete Ground Floor System that is tried, tested and trusted in over 80% of homes in The Netherlands. Thermal, Structural, Sustainable. What is Spantherm? 4 Spantherm Contents by Creagh 5 Why Choose Spantherm 6 Spantherm Product Range 9 Thermal Performance 11 What is Spantherm 5 Why Choose Spantherm 6 Spantherm Product Range 9 Thermal Performance 10 Construction Detail - Ventilated Floor 12 Construction Detail - Wooden Frame 13 Spantherm Load Spans 15 Design Specifications 16 The Screedless Solution 20 The Complete Service Package 23 Story Board 24 Case Studies & Testimonials 27 Supply only Projects 29 Associated Products for Home Builders 31 Next Step - Contact Details BC Spantherm Load Spans 11 Construction Detail - Traditional Block Construction Perpendicular to external wall 12 - Traditional Block Construction Parallel to external wall 13 - Timber Frame Construction Perpendicular to external wall 14 - Timber Frame Construction Parallel to external wall 15 Design Specification 16 Screedless Solution 21 Complete Service Package 23 Story Board 24 Case Studies & Testimonials 26 Supply only Projects 29 Associated Products for the Home Builder 31 Contact Details BC

3 Spantherm by Creagh What is Spantherm? Spantherm is a pre-insulated precast concrete flooring system designed specifically for residential and mid-sized commercial ground floors. The composite slab combines structural concrete and high performance Expanded Polystyrene (EPS) insulation to provide a superior, structural thermal floor. This structural flooring system is mechanically placed, using lorry-mounted cranes to improve Health and Safety on-site, reducing labour, waste, risks and cost. The floor is installed quickly and is thermally efficient and affordable. Creagh Concrete Products Ltd. is a long established company that specialises in the design, manufacture and installation of structural precast concrete products throughout the UK and Ireland. Creagh has grown to become one of the largest and most innovative producers of concrete products for a diverse range of market sectors, throughout Ireland and the UK, including construction, civil engineering, house building, landscaping and agricultural. Creagh designs, manufactures and supplies an extensive range of concrete products. The company operate from its head office in Toomebridge, with bases at Hoveringham, Nottinghamshire, St. Neots, Cambridgeshire and Newbridge, Edinburgh. The ethos of the company is the manufacture of quality products. Creagh is committed to providing products and services that meet customers specific contract and project requirements. Creagh Concrete Products Ltd.have developed and will maintain an Integrated Management System that conforms to the requirements of: ISO 9001: 2008, ISO 14001:2004, OHAS 18001:2007 Creagh have recently been accredited with BES6001 Responsible Sourcing of Construction Materials Certificate with a very good rating across all products. Creagh is committed to conducting their business with integrity, consistency and reliability. Business growth is facilitated through continuous product development, investment in state of the art production technology and the on-going training and development of all employees. Creagh s professional and dedicated workforce is committed to providing total customer satisfaction by treating customers as partners. Newbridge Toomebridge Hoveringham St. Neots 4 5

4 Why Choose Spantherm Benefits offered by the Spantherm System Economical Eliminates manual handling and waste cost - Spantherm is the Commercial Choice. Nationwide Service Team Spantherm operates from a growing number of bases throughout the UK and Ireland. Thermal Performance Achieve a U-value as low as 0.12W/m2K based on a P/A ratio of 0.6, dependent upon specification Design & Engineering Service Spantherm s Technical Team provides a bespoke design for each individual project including floor design layout, thermal and structural calculations in line with Building Control requirements. CDM Compliance Design out the risks associated with manual handling, trips, slips and falls on-site by specifying the Spantherm System. Quality Control Spantherm is an integral concrete and insulation system, providing consistently high product quality produced in a factory controlled environment. Product Quality Units designed to BS EN :2004 Eurocode 2: Design of concrete structures and BS EN 13224:2011 Precast concrete products Ribbed floor elements Manufactured in accordance with ISO 9001, ISO 14001, OHSAS Durable and Robust Design working life of 50 years in accordance with requirements of exposure class XC3. All Weather Construction Spantherm installation is unaffected by adverse weather conditions. Health & Safety Fully trained and certified Health & Safety compliant installation teams. Eliminates manual handling and reduces associated health and safety risks on-site. On-Site Removes the need to store or work with ground insulation materials on site. Early Completion No drying out time required. Provides immediate safe working platform. Unique Fast Track Service Spantherm s experienced installation teams install your floor within 3 hours* using off-loader lorries. The teams grout the units, leaving a complete structural sub floor. *Based on an average floor area of 90m 2 No Camber Spantherm is completely flat providing a level base upon which blockwork, timber frame and other types of buildings are constructed. No Structural Topping Required Spantherm is a structural floor and requires only a self-levelling compound as opposed to other systems which require expensive structural finishes. Services easily accommodated Penetration for services are incorporated at point of manufacture. Sustainability Concrete is one of the most versatile, durable and cost effective building materials available. It is also environmentally sustainable with green credentials that out-perform both steel and timber. When combined with expanded polystyrene insulation, it can significantly reduce the carbon footprint over the lifetime of a building. EPS (Expanded polystyrene) is rodent-proof and offers no nutrient attraction to vermin. It is not affected by water, thus ensuring that moisture contact will not lead to deterioration of the product or its performance. EPS is non-toxic, chemically inert, non-irritant and rot-proof. Designed to meet Building Control s revised specifications and the Code For Sustainable Homes. Complies with Part L of the 2010 Building Regulations and can help to achieve Level s 3-6 of Code for Sustainable Homes subject to specification. 6 7

5 Spantherm Plus is capable of achieving a flooring U-value of 0.12W/m 2 K Spantherm Product Range The Spantherm product range can be suited to your individual project requirements. Spantherm Standard 375mm Spantherm Standard is capable of achieving a U-value of 0.18W/m 2 K based on a P/A ratio of 0.6. Spantherm Standard has a recessed profile and can help achieve Code for Sustainable Homes Level mm Spantherm Advance 375mm Spantherm Advance is capable of achieving a U-value of 0.14W/m 2 K based on a P/A ratio of 0.6. Spantherm Advance is chosen by those focused on lowering their U-Values and is designed for those working towards Code for Sustainable Homes Levels 4& mm 375mm Spantherm Plus 1200mm Spantherm Plus is capable of achieving a U-value of 0.12W/m 2 K based on a P/A ratio of 0.6. Spantherm Plus is a full depth, high density polystyrene. This product is chosen by home builders who are designing a passive house and are working towards Code Levels 5 & 6 of the Code for Sustainable Homes. 8 9

6 Thermal Performance Thermal calculations have been carried out for a range of typical perimeter / area ratios in accordance with BS EN ISO 6946 and BS EN ISO The table below provides an overview of the U-values achieved using expanded polystyrene insulation with thermal conductivities of 0.038W/mK and 0.031W/mK respectively. U-value (W/m2K) Perimeter / Area Ratio Spantherm Standard ( λ90/90 = 0.038W/mK ) Spantherm Advance ( λ90/90 = 0.038W/mK ) Spantherm Plus ( λ90/90 = 0.031W/mK ) Spantherm Standard Spantherm Advance Spantherm Plus Floor element U values Note: The structural concrete has a thermal conductivity of 2.2W/mK Spantherm Load Spans Spantherm is a structural floor and offers excellent ground floor spanning capabilities for residential and mid-sized commercial construction projects. Domestic Live Load of 1.5kN/m2 Floor Finish No Partitions *Deflection is Limiting Factor in this instance. Stud Partitions (1kN/m2) Maximum Clear Span (mm) Blockwork Partition (6kN/m) 100mm Concrete Screed mm Concrete Screed mm Concrete Screed mm Self Levelling Screed mm Self Levelling Compound* Timber Battens

7 Construction Detail Traditional Block Construction with Insulated Precast Floor (Spanning Perpendiular to External Wall) Construction Detail Traditional Block Construction with Insulated Precast Floor (Spanning Parallel to External Wall) NB. Please consult building control/local authorty for regional advice and guidance NB. Please consult building control/local authorty for regional advice and guidance 12 13

8 Construction Detail Timber Frame Construction with Insulated Precast Floor (Spanning Perpendiular to External Wall) Construction Detail Timber Frame Construction with Insulated Precast Floor (Spanning Parallel to External Wall) NB. Please consult building control/local authorty for regional advice and guidance NB. Please consult building control/local authorty for regional advice and guidance 14 15

9 Design Specification Spantherm units are designed to BS EN :2004 Eurocode 2 and BS EN 13224:2004 Precast Concrete Products Ribbed Floor Elements. The units are manufactured in accordance with ISO 9001 and ISO Quality Management Standards Services All service holes are formed during the manufacture of the slabs, our standard service notch is 200mm x 200mm. Please contact the Spantherm Technical Team if larger openings are required. Partitions Can be built off the floor providing these have been allowed for in the design. Generally 6kN/m blockwork walls run parallel to span (load shared between ribs of adjacent units). Walls that can be built off the floor will be indicated on layout drawings. Cavity Wall Insulation Creagh Self-Levelling Compound Spantherm Unit DPC Grout Creagh Self-Levelling Compound Spantherm Unit Localised Bearing Point Concrete Element Localised Bearing Point Concrete Element Blockwork Support Insulation Element Blockwork Support Garages Domestic garages are designed to carry a distributed load of 2.5kN/m 2 or a concentrated load of 9.0kN. Finishes minimum: 50mm concrete screed with a minimum compressive strength of 25N/mm 2 reinforced with A142 steel mesh applied directly. Insulation Element Building Regulations Spantherm will provide insulation levels which comply with Part L of Building Regulations England and Wales; Part F, NI and Section 6 for Scotland. Each floor s thermal performance needs to be assessed individually in accordance with EN ISO 6946:2007 and EN ISO 13370:2007 to comply with the 2010 edition of Part L of the Building Regulations. Standard Dimensions 1200mm wide x 375mm deep; 900mm wide x 375mm deep; 400mm wide x 375mm deep Grout - 30N concrete with an aggregate size of not more than 10mm 16 17

10 Design Specification Bearing Spantherm requires a bearing of 100mm on masonry. Slabs can be supported by the inner skin of the cavity walls to provide side bearing where this has been allowed for in the design. Intergrated Heating Underfloor heating coils can be incorporated into Spantherm flooring during manufacture to maximise the benefits of thermal mass and reduce floor finishing heights For further information please speak with the Spantherm Technical Team Spantherm Unit Cavity Wall Insulation Creagh Self-Levelling Compound Spantherm Unit DPC Grout DPC Ventilated Pipe Localised Bearing Point Concrete Element Concrete Element Blockwork Support Insulation Element Blockwork Support Heating Coils Insulation Element 18 19

11 Screedless Solution Spantherm provides a flat finished structural sub floor without camber. Therefore there is no requirement for screed. The system is suitable for use with proprietary selflevelling compound (1550 Universal) with a minimum bed thickness of 3mm to 50mm, dependant upon specification. Creagh SLC 1550 Universal is a fibre reinforced cement based topping, manufactured from a controlled blend of special sands, cements and synthetic polymers. This gives a high quality floor product which is self-levelling and smoothing. Spantherm screedless can be used with a number of different finishes: Carpet (and underlay) Vinyl (over latex) Tiles (with flexible adhesive) Wooden Floor 20 21

12 The Complete Service Package Team Spantherm offers a unique comprehensive service, from design of floor to supply of elements to on-site installation. Engineered Floor Design & Thermal Calculations The Spantherm team provide a comprehensive design service which includes provision of CAD based drawings along with all relevant structural and thermal design calculations. Site Survey Upon request, we shall survey your site, to ascertain dimensions of your building, enabling us to prepare a CAD layout drawing. Alternatively, we can agree to take measurements from plan. As part of the site survey we consider site access, bearing configurations, health and safety issues, plant locations and obstructions. Rapid nationwide delivery The Spantherm fleet is extensive and covers the length and breadth of the UK. Floors Manufactured to order As each project is unique, Spantherm products are made to order to ensure individual site requirements are met. Service holes are created in the manufacturing process Provision of Engineer s design certificate and calculations On completion of your project, the Spantherm team will issue a design certificate along with calculations for your project. Installation & Grouting Service Using the Spantherm flooring system removes the need for the contractor to arrange any of the following; Cranes Ready mixed concrete supplier Storing and cutting of insulation on-site Mesh reinforcement Curing time Formwork Benefits: Screedless Solution. Removes requirement for structural screed Significantly reduces on-site construction time with a single day visit Structural sub floor - ready to build off next day Eliminates cranes, formwork and the need to fix polystyrene on-site Provides a thermally efficient sustainable, structural and cost effective floor. Factory produced floor, giving consistent insulation and concrete coverage over the span of the unit

13 Storyboard 1. The Spantherm Technical Team receives plans to provide a free quotation for Spantherm. 2. The Spantherm National Sales Team is on hand to provide sales and technical support 3. Site measurement and survey are performed upon request 13. Installation 14. Installation 15. Installation 4. Spantherm Team provides technical drawings for construction on site 5. Spantherm products are made to order 6. Spantherm products are manufactured in locations in GB and NI 16. Installation 17. Installation 18. Spantherm units are grouted to ensure structural integrity of the floor 9am 7. Spantherm is delivered on off-loading lorries (site dependant) 8. The experienced Spantherm Fitting Team begins the installation process 9. Spantherm Fitting Team is highly skilled and health and safety accredited 19. Spantherm floors are watered prior to grouting 20. The grout is placed on the floor and spread by Spantherm fitting operatives 21. Grouting process is completed in approx 1 hour (Based on 90m 2 flooring area) 12pm 10. Service holes are created in the manufacturing process 11. Installation 12. Installation 22. Spantherm units are completed on site in 3 hours (Based on average house size on 90m 2 ) 23. Contact the Spantherm Technical Team for guidance on loading the floor with blocks 24. Spantherm is structural, flat floor ready for building on the following day

14 Case Studies & Testimonials Case Study 1 Case Study 2 Case Study 3 Contractor: Site: DB Contracts Jordanstown, N Ireland Contractor: GB Buildings Contractor: Site: Econekt Dumfries and Galloway, Scotland Site: Hatfield, Luton, England DB Contracts are building a high quality housing development on the outskirts of Belfast. Spantherm floors were fitted to the second phase of this development to 20 housing units. John Dobbin, owner of DB Contracts used Spantherm because of the high thermal properties. He stated The Spantherm product we used added great benefit to our site operations. The floors were measured by the Spantherm team and a construction drawing issued for approval within a matter of days from placing the order. The Spantherm floors arrived on site a week after placing the orders and the units were fitted in half a day. This made a huge difference to the speed of construction. The thermal properties provided by Spantherm means that the homes are of a higher specification and add value to not only us but also the end user. Spantherm plus was used to build a Care Home for GB Buildings. Every slab had one skewed end. These were manufactured to specification and this project was fitted in one day (300m 2 ). This project was used as the approval site for the BBA who inspected our processes and were happy with the standard achieved. Tim Deane from GB Buildings commented, We decided to use Spantherm on our project in Hatfield because commercially it made sense and practically it appeared to offer an improved solution to our ground floor requirements. The units were installed at our Hatfield site and we experienced a quick installation that improved health and safety on site and left a working platform for the next day. We have been pleased with our choice and following our experience, we plan to use Spantherm on other projects. Econekt work with mainly self-build clients to build high specification, eco-friendly homes. They use insulated materials to provide a low U-Value, thermal home to the end user. Colin McLachlan from Ecoknect stated As a Company we are always looking for new construction materials and methods that will allow us to have the edge on our competitors and offer our customers quality products and value for money performance. With this in mind we considered a number of different methods for constructing ground floors and chose Spantherm to trial in a one-off project. At every stage of procurement and installation all staff members at Creagh from design office to site labour, were professional and efficient in their approach to our project. When the construction is complete the use of Spantherm will have contributed considerably to the sustainability and thermal performance of our project. This together with the added benefit of having a solid and safe working platform for all follow on trades has convinced us to incorporate Spantherm as a standard component in all of our future construction projects

15 Supply Only Projects Handling Spantherm The Spantherm team provides a complete delivery and installation service. The majority of our customers will not be involved in lifting or stacking units. If this does occur, the following advice should be adhered to: Spantherm units should always be placed on level ground The units should be supported at 4 level points at corners. Use purpose made lifting hooks or chains at each end. Units can be stacked directly on top of each other without using support in between. Support required only at bottom. Maximum stack of 4 units high. Grouting of Spantherm units Spantherm provide a comprehensive grouting service. However, when undertaken by customers, the following procedures should be followed: Ensure that all debris is cleared from joints between units. Water to be sprayed on joints prior to grouting Floors to be grouted before they are loaded Grout to be 30N concrete with an aggregate size of not more than 10mm. Grout should be fully cured before floors are loaded NOTE: It is essential that the correct grouting procedure is followed to ensure the structural integrity of the floor. Ensure joints between units are grouted Grout with the correct mix Make sure the grout is fully cured before loading Take measures to protect the grout from inclement weather 28 29

16 Creagh Products For The Home Builder Creagh Concrete Products Ltd offer a wide range of products for the house builder: HomeSPAN Reinforced Flooring The homespan flooring system comprises of flat precast concrete planks generally 600mm wide and 150mm deep. It is designed for residential use in ground and upper floors. HomeSPAN slabs are capable of carrying domestic loading for spans up to 5m. Prestressed Hollowcore Flooring Creagh Concrete manufacture an extensive range of prestressed Hollowcore flooring units from150mm deep to 400mm deep. These products are generally used in upper floors in apartments and multi-storey dwellings. Precast Stairs This product range comprises of straight, return and curved stairs and are designed and made to order for each individual project. They are available in a range of classes A-C

17 Contact Us The Spantherm Team is available to discuss your project requirements and provide advice regarding designs, U -values and costs. Please contact us to arrange: A face to face meeting with one of our representatives A Site Survey A CPD Technical Seminar Or to discuss your specific project requirements Plans England & Wales Scotland Northern Ireland Ireland On receipt of architectural plans we will provide a complimentary Design and Estimating package Spantherm@creaghconcrete.com ENGLAND (Midlands) Creagh Concrete Products Ltd. Thurgarton Lane Hoveringham Nottinghamshire NG14 7JX Tel: ENGLAND (Southern) Creagh Concrete Products Ltd. 152 Great North Road The Green, Eaton Socon St Neots, Cambridgeshire PE19 8EJ Tel: IRELAND Creagh Concrete Products Ltd. Blackpark Road Toomebridge County Antrim BT41 3SE NI : ROI: SCOTLAND Creagh Concrete Products Ltd. Newbridge Industrial Estate Newbridge Edinburgh EH28 8PJ Tel: