Poundfield Precast B114233 Beam and Block Concreate Flooring Installation Guide

Choosing the Right Beams:
Ensure to select the appropriate beams based on the project requirements. Consult with a member of the sales team for guidance.

Block Specification:
Confirm the block specifications early, as they are crucial for pricing and design considerations. Refer to Architect/Engineer plans for details.

Installation Process:
Follow these steps for installation:

Prepare the foundation according to the project requirements.

Lay the beams in the designated pattern, ensuring proper alignment and spacing.
Place the blocks securely on the beams, ensuring they fit snugly without any protrusions.

Verify that the blocks are correctly positioned to support the intended loads.

Maintenance:
For wet-cast finish beams, no additional maintenance is usually required. However, extruded beams may need some cleaning to remove imperfections before block placement.

Beam & block flooring

Poundfield Precast flooring systems carry the CE Mark Accreditation British Standard EN 15037-1:2008 so you can be assured of receiving consistently high quality precast concrete products manufactured to meet with current construction and installation best practices.

Beam & Block suspended flooring systems are cost-effective, easy to install and can be laid in all weathers. They can be used for both ground and upper floor levels in domestic and industrial buildings and only minimal levels of excavation are required.

Poundfield Precast Flooring Division specialises in the following sectors:

Large Contract Sites

Installations and Project Management
Self-build support and technical consultations

Extensions to domestic houses
Full technical support to builders merchants

Commercial and bespoke projects – from patios to railway platforms

Always in stock and cut to 25mm increments for quick delivery,our beams offer the perfect solution to your flooring needs.

What services do we offer?

Full packages on projects where applicable and unrestricted

Tailored designs to meet your requirements
Both beam and block and EPS systems available at request

U-values as low as 0.08W/m2K
BBA approved and CE accredited

Manufactured to 25mm increments
A range of infill blocks – all blocks are transversed tested for flooring

Our beams

Our precast concrete beams are suitable for use in a number of building projects, from one off properties to multi-million-pound developments.
Poundfield beams are made from a precision steel mould using pre-stressed steel wires covered in a bespoke concrete design to give a high quality product, this process enables Poundfield to have a superior finish to other suppliers known as Wet-Cast finish or A-Grade.

Wet-cast beams are more operative friendly than extruded beams. With the smooth wet-cast finish, no further work is required on the product.
Extruded beams are commonly left with further maintenance required on the beams by means of removing snots and burrs. This maintenance needs to be done prior to block placing otherwise blocks sit proud/uneven into the floor.
One of the key things to get confirmed early is the block specification for sites. These can often be found on the Architects/Engineer plans and is vital for the pricing element of the project and most importantly the design of the floors.
Each block has it’s own self-weight and guide to where they can and cannot be used.

A few examples of universal infill blocks – CEMEX 1400, Lignacite GP, Celcon 3.5N Standard. When a build is getting to digging stage on foundations, the question of blocks must be asked.
For higher loadings, the W1 and D1 beams can span even further and help to reduce foundations costs.
To select the correct beams for your project, speak to a member of our sales team.

Residential beams

Table based on finishes of 1.80kN/m2 and 1450kg/m3 medium dense blocks

Commercial beams

Table based on finishes of 1.80kN/m2 and 1450kg/m3 medium dense blocks

Figures are clear span – including 200 mm bearing (100 mm either end)

Installation guide

Before installing the Poundfield beam system the following checks must be carried out:

Over-site has been cleared of vegetation and relevant weed-killer treatments have been carried out
Sufficient void from ground to underside of beams has been checked and confirmed (Architect or Local Building Control will confirm this based on ground conditions – standard minimum of 150mm+)

Confirmation on whether a DPM is required in cases where ground conditions are poor
DPC has been laid over the internal substructure ready to receive the beams
Drainage is installed in its required positioning before beams are laid and all services are piped out or marked for spacing requirements

Ensure the adequate ventilation requirements have been met and lintel sets are cured and ready for laying on-top of

Ensure you have the correct lifting equipment if using mechanical plant, lifting points should be within 300mm of each end of the beam
If using manual labour, please ensure that the correct PPE is used as to avoid injury or harm to hands
100mm nominal bearing is required on the beams at each end based on brickwork substructures

Identify and adhere to the recommended start points for your project, these will be indicated by the Beam office if you are unsure
Ensure that all doubles and triples are placed where indicated on the floor plans
Use infill blocks as spacers at either end of the beams, the remaining infill blocks can then be dropped into place as required

Trim any blocks as required around protruding drainage pipes & services
Cut blocks where required and prep substructure walls for slipbricks

These guidelines are recommended to be followed to ensure a smooth installation of your flooring system.
A risk assessment & method statement of your site must be carried out by a competent person prior to your install. If you are unsure at any stage of your install please contact our sales office.

Once the beams and infill blocks are installed, the ‘Wet Works’ are now required to complete your floor. To do this, follow these simple steps:

Mix up a standard brick mortar for bedding the slip bricks down
Slipbrick locations can be found at either ends of the beams in the floor and along a block strip onto a substructure wall. These will be indicated on your design
Standard practice is 2 no slip-bricks per 440mm spacing (Maximum block) and 1no slip-brick per 215mm spacing (Narrow block)

Please ensure that the relevant cross-ventilation airflow between internal bays is met to conform to Building Regulations
Once the floor has been completed, wet heavily with a hose ready for grouting
Mix up a grout mix of 4:1 sharp sand – cement and brush over the floor and into the joints with a stiff brush

Mix up a concrete mix using a sufficient aggregate to a C30 standard and deposit within the voids between any doubles or triple beams. This is to create a unified bond between the beams.
Do not grout Garage Floors. These must remain un-grouted due to Composite Action.

Once the Wet Works have been completed and your floor has set on the concreting. Prepare the floor for screeding.

Brush off any excessive detritus from the floor to ensure a smooth level surface
A DPM may be required – please confirm with Architect specification / Local Building Control for affirmation if required
Install the specified insulation product, ensuring the thickness and grade matches what has been specified

Confirm with Architect/Engineer for your project on the screed type/reinforcement required – Garages must have a reinforced screed often utilising a mesh reinforcement A142 or A98
The screed must then be installed by a competent person/s.

Stacking and lifting guide

The flooring beams must be stacked the right way up, with timber bearers placed just in from the ends, (maximum four times unit depth, “H”) vertically above one another.

Care should be taken in the stacking and general handling of the units, taking into account the weight of the products, the stability of the stacks and the load carrying capacity of the ground.
Timber bearers must be lined vertically through the stack at a maximum 250mm from the end of the units.
In addition to the precautions to be observed when stacking, e.g. the position of bearers, care must be taken to ensure that the ground or surface on which the components are to be stacked is suitable.

The ground must be firm and level, and wherever possible stacking of components should be on firm hard-core or oversite concrete.
The height to which components can be safely stacked on site will be greatly influenced by the condition of the ground on which they bear.
Another prime consideration should be the height to which a man can reach to pass lifting chains or slings around the components.

Similar length units should be stacked together.

Safety warning

Protective clothing should be worn.
T-beams compact in on themselves when lifted, KEEP HANDS CLEAR TO AVOID INJURY.

Ensure good manual handling techniques.

Beam products are generally delivered on articulated vehicles therefore appropriate hardstanding and access is essential.
The Contractor must inspect the floor units at the time of delivery on supply only contracts and sign the delivery ticket, as no liability for damage can be accepted at a later date.
Ensure before lifting that the crane is sited on firm level ground and there is sufficient clear working area for turning and slewing with no overhead obstructions.

Poundfield EPS Flooring

Expanded polystyrene (EPS) is proving to be an ideal insulating material in the construction of floors using prestressed concrete beams. PEPS is a lightweight, rigid, plastic foam insulation produced from solid beads of polystyrene. It is made up of 98% air and 2% plastic.

What are the benefits?

Quick and easy to install
Cost effective against other block and beam systems
Can be laid in wet conditions – PEPS is moisture and rot proof

Reduced wastage as standard sized panels are used for maximum efficiency
Excellent thermal properties resulting in low thermal conductivity
A+ green guide rating

Exceeds the thermal requirements of part L of the building regulations without the need for additional insulation.
Eliminates the problems associated with part C of the building regulations relating to site preparation and resistance to contaminants and moisture.
BBA certified number 17/5431 product sheet 2

PEPS acheiving 0.11 – 0.12 and lower u value 2025 Regs

As major manufacturers and suppliers of beam and block flooring Poundfield Precast has introduced PEPS (Poundfield EPS flooring) as a way for our customers to supply more environmentally-friendly solutions to help reduce heating costs by improving thermal insulation and saving wasted energy.

The use of PEPS in conjunction with pre-stressed concrete beams is a highly effective, thermally efficient way of achieving and exceeding the thermal requirements of part L of the building regulations without the need for additional insulation.

PEPS will maintain its performance throughout the lifetime of the building and is therefore a long-term and cost-effective way to reduce heating costs in a property. EPS has obtained an A+ green guide rating.
Poundfield PEPS system can be installed in conjunction with underfloor heating systems which are becoming increasingly popular.

Grades of PEPS available
PEPs are available in both white and grey in multiple grades (70/120/150) to achieve your required U-value target. The higher the number, the denser the PEPS, and the better the thermal conductivity. For full details please see the technical specifications below.

Difference between white and grey PEPS
The white is our standard option whilst the grey EPS contains tiny chemically modified particles that reflect heat radiation and gives the material its grey colour.
These infrared absorbers and reflectors lower the thermal conductivity of the material offering a thickness reduction of about 20% against standard white EPS.

Examples of standard dimensions of EPS infill panels:

Frequently asked questions

Is EPS flooring more expensive than traditional block and beam and which is more cost effective?
Depending on the specification of the job, Poundfield’s PEPS system can prove to be more cost effective than traditional beam and block. New planning conditions on floor U-values under Part L results in a reduction in overall floor values from 0.45W/m²K to 0.25W/m²K. We are able to provide full costings and advice on which system will be the optimal solution for your projects.

How do you store PEPS flooring?
The PEPS infill blocks are delivered on 5’ x 4’ pallets and are shrink wrapped. The PEPS infill blocks and top sheet can simply be stored using Herras fencing and weighed down using concrete blocks to prevent them being blown by wind.

Which beams from Poundfield will PEPS work with?
Our PEPS System is compatible with all of our range of beams (N1, T3, W1 and D1).

Does it get damaged by rain?
No. PEPS is waterproof and doesn’t shrink or rot, therefore it can be laid in all weathers without any concerns.

Can you walk on PEPS flooring or will it damage the flooring?
The PEPS system can be walked on after installation within reason, however we do not recommend storing materials or heavy goods on them. Please ensure that your boots are clean before walking on the PEPS to avoid having to clean the blocks before laying the top sheet and membrane.

How do you install PEPS flooring?
Once the concrete beams have been installed the infill blocks of PEPS are placed in between the beams in much the same way as you would place a concrete block. A top sheet of EPS is then laid on top, followed by a membrane and covered with self-levelling concrete.

A zero carbon future

The necessity to limit global warming to no more than 1.5ºC above pre-industrial levels has been well documented and publicised. The science could not be any clearer. The world has to reduce CO2 emissions to as close to zero as possible by the middle of this century.

The UK Government has committed to reaching net zero by 2050 and every business, organisation and individual has a part to play in achieving this.

Concrete is the most used material on the planet and as a consequence is a significant contributor of CO2. Up to 90% of greenhouse gas emissions associated with concrete are in the cement1. As a building material, concrete cannot be matched. But as the world’s third highest source of man-made CO2, greener options have become of even greater importance.

As a major precast concrete manufacturer we recognise the contribution we can make to help our customers lower their carbon footprint and this is now our major driver within the business.
1 Source: Low Carbon Concrete Group

Lowering the carbon footprint of concrete

Concrete is made up of aggregates, water, cement and air. Of these four ingredients, aggregates make up the largest amount of volume and fortunately are low in embodied carbon.
However, cement has the highest embodied CO2, and this is where the focus has been to find alternatives to OPC (Ordinary Portland Cement), to reduce the carbon footprint of this important building material.
Reducing our carbon footprint in construction can be achieved in various ways, whether that be in using cement-free options, by partial CEM 1 replacement or considering different reinforcement solutions.

Introducing Greenbloc

2021
In 2021 we launched Greenbloc Ultra which was the UK’s first cement free ultra low carbon dense carbon block, offering carbon savings of up to 77%.

2022
In 2022 41% of PPG (Precast Products Group) major infrastructure projects involved Greenbloc technology.

2023
We now offer three levels of Greenbloc. Standard, premium and ultra, offering carbon savings of up to 50%, 70% and 80% respectively.

Currently, within British standards there are a number of ways to reduce embodied carbon by reducing the percentage of clinker in a mix. The use of ground granulated blast-furnace slag (GGBS) for example, instead of clinker, can have a significant effect on lowering embodied carbon. CEM III/B contains up to 80% GGBS and has a 73% lower embodied carbon than Portland Cement (CEM I).

FAQs

What are some examples of universal infill blocks?

Some examples include CEMEX 1400, Lignacite GP, Celcon 3.5N Standard. Consult with your team when reaching the foundation stage for block selection.

How do I handle higher loadings with the beams?

For higher loadings, consider using W1 and D1 beams as they can span further and help reduce foundation costs. Consult with our sales team to determine the best beams for your project

What are the advantages of Greenbloc?

Products within our Greenbloc range all offer carbon savings compared with using OPC (Ordinary Portland Cement).

How do you achieve the carbon saving?

CCP Greenbloc technology is based on reducing cement which is the key material in concrete that contributes the highest amount of carbon. We replace the cement with low and ultra-low carbon cement alternative materials that can be manipulated to perform in the same way as cement.

Do your blocks have the same u value?

Yes they do. Our low carbon Greenbloc blocks have the same performance, same cost and lower carbon footprint.

Do you have any independent results to verify its performance?

To verify our carbon reduction claims we have 3rd party verified EPD (Environment Product Declaration) to prove that our carbon reduction values and data are as specified and reported.

Do your blocks which feature the Greenbloc technology have the same fire resistance as a conventional block?

Yes they do. There is no difference. All Greenbloc products perform to the same specification, performance, quality and aesthetic characteristics as 100% cement versions.

Timeline of events from enquiry to delivery

Enquiry
Customer to send drawings across to Poundfield Precast along with covering letter of what is required.

Quotation
Poundfield Precast will produce a quotation for the customer detailing price, extras and advising of proposed lead times (this period includes time for drawings to be produced). If there is any ambiguity surrounding what is required then we will send back a marked up plan detailing required supports and span directions. Average time 2-3 days for a quote.

Order
If the customer is happy with the price and delivery period we will require a written instruction to proceed.

Drawings
Once an order is received we will produce fully detailed layout drawings to be sent back to the customer.

Approvals
Customer is to approve our layout drawings. Approvals required within 24 hours to adhere to lead times set out in quotation.

Delivery
Beams will be manufactured and delivered following approvals. Confirmation of exact delivery vehicle and dates will be confirmed at this point. During busy periods lead times may be extended.

Supporting your business

If you would like some sales support for your business or branch then please speak to one of the flooring team who would be happy to organise some information to be sent out to you.
We can offer branded banners, bollard covers, flags, floor graphics and merchant counter packs with specification sheets for our beams and floor options.

We can also provide training at our factory site for key members of your team to fully understand Beam and Block flooring. Our comprehensive training session will discuss in detail our beam types, demonstrate a beam and block install to help understand the process of how the flooring is installed onto the site and a chance to tour our facility to see how the beams are cast and cut.

One of the benefits of being a stockist is that we will provide layout designs for all projects taken from yard or direct as a standard, along with full technical support.

Retaining walls range

ALFABLOC®

Connect the blocks to create one solid wall
Out performs the competition
Easily transported
Can be lifted without chains or shackles
Fast and easy one-man installation
Easily configured meaning you can change the layout in minutes

L-BLOC®

Easy installation, with tongue and groove system.
Pre-stressed and interlocking, to create robust wall.
Use for grain walling, waste separation, bulk storage, recycling materials.
Accommodates loading from either side of the wall. No reverse heel.

TAPERBLOC™

Freestanding
Ideal for grain walling, waste separation, bulk storage, recycling materials
No protruding toe makes access to stored material easier
Easy to manoeuvre and reconfigure to change structure

PRESTRESSED PANELS

Lengths from 1m to 6.5m
Thickness from 100 to 300mm
Interlocking tongue and groove
Cast in fixing points
Can be used with steel frames
No foundation required
Easy to install

BETALOC®

Ideal retaining wall system
Rapid and flexible construction
Lightweight
Easy installation
Immediately useable
Expandable and moveable
Permanent and temporary applications
Landscaping, flood defences or site security barriers.

ALFASTOP®

Protect your workforce and visitors from hazards on site.
Instant site security from the moment of delivery
Reconfigure or extend your fencing
Temporary or permanent solution
Reusable for multiple applications
Alfastop® is designed specifically to work with a standard Heras fence

Precast concrete fencing products

Allen Concrete manufactures precast concrete products for the fencing and building industries. Plants in Surrey and Northamptonshire utilise modern production methods and machinery backed by careful quality control for the mass production of a large range of standard products. Large stocks and regular, flexible, delivery options ensure the fast and efficient despatch of products throughout the country.

Recessed Fence Posts
Slotted Fence Posts and Gravel Boards
Wildlife Friendly Gravel Boards
Strained Wire Concrete Fence Posts
Universal & Ornamental Chain Posts
Chain Link Fence Posts
Concrete Palisade Fencing
Bollards and Barrel Posts
Morticed Fence Posts

Precast Concrete Spurs

Bespoke products and services
With extensive experience and close relationships with various high quality specialist manufacturers, we are well placed to undertake the sourcing and supply of a range of bespoke structural and non-structural precast concrete products made to customer specification in large or small quantities such as:

Pier Caps and Copings
Marker Posts
Window sills and surrounds

Marketing support for your branch

We can offer branded banners, bollard covers, flags, floor graphics and merchant counter packs with specification sheets for our beams and floor options.

For further information please contact us on 01449 723150 or email beamandblock@poundfield.com
Poundfield Precast Limited, The Grove, Creeting St Peter, Ipswich, Suffolk IP6 8QG

Documents / Resources

Poundfield Precast B114233 Beam and Block Concreate Flooring [pdf] Installation Guide
B114233 Beam and Block Concreate Flooring, B114233, Beam and Block Concreate Flooring, Block Concreate Flooring, Concreate Flooring, Flooring

References

User Manual

Poundfield Precast B114233 Beam and Block Concreate Flooring

Product Usage Instructions