INSULSLAB SFRC

PEEL INDUSTRIAL ESTATE
CHAMBERHALL STREET
BURY
LANCASHIRE BL9 0LU

Tel: 0844 576 6726
Fax: 0161 447 8333

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Suppliers of: Shallow foundation system polystyrene raft foundations

A Complete foundation system that offers both cost savings and excellent thermal performance.

Insulslab is a complete BBA Certified and Patented foundation system, based on a type of raft foundation which comprises a series of interlocking expanded polystyrene pods, forming a substantially rigid ‘waffle’ shaped slab (waffle foundation system). Steel fibre reinforced concrete is poured over the top to form the finished foundation.

Insulslab is an innovative high quality, patented (GB2385071) foundation system that is suitable for use on a wide range of soil types for both residential houses and commercial constructions of up to four stories high.

Insulslab offers substantial benefits for the developer, architect, structural engineer and ground worker: -

  • Increased speed of construction, reduced labour costs, excavation costs and reduced waste costs.
  • Excellent thermal performance - typical U-values of around 0.10 - 0.12W/m2K, depending on P/A ratio.
  • Significant cost savings - a typical saving of 25 - 33% over traditional beam and block/raft.
  • Shallow foundation system requires minimal excavation.
  • BBA Certified and accepted by the NHBC/LABC and Premier
  • Compliance with Part L without the need for an additional layer of insulation and screed. 
  • Meets Part E (Section 5 Scotland) sound insulation requirements when used as proprietary Robust Details construction.
  • Code for Sustainable Homes & BREEAM credit scores. Green Guide Rating.
  • Perfect for brownfield sites and contaminated soils
  • Less volume of concrete required and no rebar and mesh reinforcement.
  • Health & Safety benefits with no heavy blocks to lift.

A complete specification and installation support service.

Insulslab’s specialist technical team, including engineering, U-value calculations and on-site technical support. General arrangement drawings and quantified costs can also be provided, as well as steel fibre reinforced concrete calculations from ArcelorMittal.

FOUNDATION Clayheave Protection .
FOUNDATION Construction Reinforced Concrete
FOUNDATION Contractors .
FOUNDATION Design .
FOUNDATION Design Shallow Depth
FOUNDATION Design and Construction .
FOUNDATION Ground Movement Protection .
FOUNDATION Systems AGREMENT CERTIFICATE HOLDERS .
FOUNDATION Systems BREEAM Credit Scores .
FOUNDATION Systems Code for Sustainable Homes .
FOUNDATION Systems Contaminated Sites .
FOUNDATION Systems Contaminated Sites Gas Protection
FOUNDATION Systems Contaminated Sites Gas Protection CS3/Amber 2
FOUNDATION Systems NHBC/LABC/Premier Requirements .
FOUNDATION Systems Part L Building Regulations (Section 6 Scotland)
FOUNDATION Systems Shallow Depth Minimal Dig Alternative to Traditional Piled/Vibro Foundations
FOUNDATION Systems Shallow Depth Minimal Dig Alternative to Traditional Raft Foundations
FOUNDATION Systems Shallow Depth Minimal Dig Insulating Expanded Polystyrene Pods EPS
FOUNDATION Systems Shallow Depth Minimal Dig Interlocking Insulation Pods
FOUNDATION Systems Shallow Depth Minimal Dig NHBC LABC Approved Code for Sustainable Homes
FOUNDATION Systems Shallow Depth Minimal Dig Steel Fibre Reinforced Concrete SFRC
FOUNDATION Systems Shallow Depth Minimal Dig Trenchless / No Trench Foundations
FOUNDATION Systems Waffle Systems Rafts .
FOUNDATIONS Contaminated Land .
FOUNDATIONS Finished Floor System Combined AGREMENT CERTIFICATE HOLDERS
FOUNDATIONS Insulated Ground Floor Systems .
FOUNDATIONS Over Piles .
IN-SITU CONCRETE Floors and Foundations Steel Fibre Reinforced AGREMENT CERTIFICATE HOLDERS
RAFTS Foundation Polystyrene Pods Insulating Moulds
ARCELORMITTAL (SUPPLIER) Steel Fibres for Concrete
ARCELORMITTAL INSULSLAB Steel Fibre Reinforced Concrete

Insulslab adopted for custody suite programme

April 2017

Insulslab adopted for custody suite programme

Kier Construction has adopted Insulslab for a nationwide programme of new build custody suites. Used across five sites – Alysham, Bury St Edmunds, Ipswich, King’s Lynn and Wymondham – Insulslab was specified in favour of traditional foundation techniques owing to the system’s proven efficiency gains and superior thermal performance.

Requiring minimal ground excavation, Insulslab significantly increases the efficiency with which foundations can be completed. Constructed of interlocking expanded polystyrene (EPS) pods, Insulslab is simply laid in place to form a substantially rigid 'waffle' shaped slab, with steel fibre reinforced concrete (SFRC) then poured on top to deliver the foundation up to ground floor slab level.

With speed of build a key consideration in the custody suite programme, Insulslab was used in combination with precast concrete walls. As a flexible specification, the Insulslab profile was designed with recessed channels, allowing the precast walls to be easily positioned in place.

At the Ipswich site, groundworkers LPL Construction were particularly impressed with the simplicity of system design and installation. Chris Kirk, Contracts Manager at LPL Construction, comments: "Insulslab was extremely easy to use. We'd never used the system before and initially thought we were missing something as it was so straightforward. We undertook a two pour process with the concrete which went extremely smoothly, enabling us to deliver our programme of works to the specified deadline."

Integrating the EPS insulation into system design allows Insulslab to deliver superior thermal performance without increasing floor depth. Achieving typical U-Values of 0.10 – 0.12W/m2K (depending on P/A ratio), Insulslab offers a cost effective and efficient method of thermal insulation.

Reflecting on the use of Insulslab at the Ipswich site, Mark Lockley, Project Manager for Kier, comments: "Insulslab was specified as a highly effective thermal system that could also deliver on-site efficiency gains. It has proven easy to use and we have been impressed by the responsiveness of the Insulslab technical team with design iterations and on-site support."

As structural engineers on the project, McBains Cooper also recognise the benefits of using Insulslab. Paul Cowton, Director, explains: "We have successfully used the Insulslab foundation system on a number of projects and found it to be efficient and cost effective. We will certainly consider utilising this unqiue system on future projects."

Insulslab gets Lovell Project back on track

April 2017

An affordable homes development for Milton Keynes Council was kept on track thanks to the time and cost saving benefits of the fully integrated and super insulated foundation system, Insulslab.

Housing specialist Lovell was overseeing the Briar Hill project in Milton Keynes, which comprised the construction of 13 wheelchair standard compliant bungalows on the site of a former care home. In the early stages of the project, obstructions in the ground were encountered that proved to be remnants of former foundations that had not been fully removed.

Despite a previous extensive physical ground investigation, the remaining elements of these foundations had not been struck. As a result, the ground worker had started on-site and a trench foundation system was being utilised, hence the discovery of the obstructions was likely to delay the project by a number of weeks, which in turn would delay the completion date and add to the cost.

To remedy the situation, Lovell could either dig out and break up the old foundations, which would have been time consuming and costly, or find an alternative foundation solution – which led to the specification of Insulslab.

Based on a cast in-situ foundation system, which comprises a series of interlocking expanded polystyrene pods, Insulslab is a fully integrated and super insulated foundation system. Thanks to factors such as minimal excavation, low levels of waste and fewer construction stages it is ideal for projects where time and budget are of the essence.

It took just five days to install Insulslab on all plots, which would not have been possible with beam and block or trench systems given the site conditions.

Moreover, because Insulslab does not require rebar or steel reinforcement, the Lovell team was able to use it easily on the site in spite of the limited room to manoeuvre.

"This was the first time we had used Insulslab in the Midlands," explained Richard Burns, Technical Co-ordinator, Lovell Midlands. "Using the system enabled us to accelerate the programme and regain the time that was lost through unforeseen circumstances without digging the ground out further. Insulslab was very quick to turn around the system designs and the thermal performance of the system helped us to achieve the Level 4 required by the Code for Sustainable Homes".

"We've been extremely impressed by the manufacturer’s prompt and efficient service, as well as the Insulslab system, and are now looking to use it at two more sites."

Bob Brennan, Director, Brennan Build & Civil Engineering – the ground worker on the Briar Hill development added: "Having previously used Insulslab on another site, I knew first hand that it was quick, easy and safe to install. It’s an excellent system for time saving, even when dealing with unexpected ground conditions, and it really helped us to turn this development around."

Michael Gilliead, National Sales Manager, Insulslab concluded: "Insulslab is a tried and tested system, suitable for a wide range of ground conditions. It really comes into its own on challenging sites and can deliver significant commercial advantages. Thanks to its flexibility and efficient installation, Insulslab can still be considered even when a project is underway – as the Briar Hill project has successfully demonstrated."

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