MILBANK CONCRETE PRODUCTS LTD
EARLS COLNE BUSINESS PARK
EARLS COLNE
COLCHESTER
ESSEX CO6 2NS
Tel: 01787 223931
Fax:
Suppliers of: Precast Concrete, Flooring, Beams & Blocks, Staircases, Landings, Hollowcore floors, concrete beams
“Delivering quality products through a sustainably conscious supply chain to help you build better”
Milbank Concrete Products is the UK’s leading manufacturer of high-quality precast concrete products. Our trading history spans over 75 years and we are dedicated to helping you succeed.
Our factory, offices and transport hub are located near Colchester on the Essex/Suffolk borders. With the A12, M11 and M25 all nearby, we are well positioned to offer a competitive service to London/Home Counties, East Anglia and the Southeast. For our specialist products including helical stairs, bespoke precast, stadia etc. we extend coverage to most of the UK.
Our team of design experts offer technical support, produce design drawings, and offer innovative design led solutions to your individual challenges. We provide valued engineering input throughout the order process to ensure you have the most efficient and cost-effective solutions available.
Our highly experienced in-house engineers and design staff provide support and advice to homebuilders, contractors, architects and engineers in the specification and design of precast and prestressed concrete products.
Precast concrete is the most commonly used building material in the world, and by manufacturing in a carefully controlled factory environment, our precast concrete is not affected by variable site conditions or the elements. With this in mind, it is a safe, reliable, long lasting and cost-effective product.
Our products are designed and supplied to exact build fit and specification which allow for improved efficiencies throughout the build process, and our range of precast components allow immediate site and finishing access following installation providing a solid footing - meaning no delays and safe access for follow-on trades.
Milbank concrete is always perfectly mixed and offers superior strength and durability in comparison to traditional, wet concrete. It is quicker than in-situ mould construction and pouring and can be made into virtually any shape. It is fireproof and will not melt at high temperatures along with being tough and durable with excellent exposure properties. It is wholly resistant to insect, pests, vermin attacks, fungus, and mildew. It is completely recyclable, and all precast units can be re-used in their entirety at the end of their life.
How we’re making a difference
We have been proactive in adapting our processes to work towards carbon neutrality, introducing both a wood pellet fuelled biomass boiler and electric vehicle charging points for staff and visitors.
On top of this, we have successfully transitioned 100% of our production machinery, including fork trucks, loading shovels, shunters, dumpers, cherry pickers and prestressed concrete manufacturing machines from the use of regular diesel to HVO – a hydro-treated vegetable oil biofuel.
By adopting 100% HVO, greenhouse gas emissions produced by our machinery reduced by up to 90%, with a 35% reduction in particulate mass and a 30% reduction of CO2 company wide.
What we offer:
Milbank Hollowcore floors are prestressed concrete units with tubular voids extending the full length of the slab creating an efficient lightweight unit. This makes the slab much lighter than other floor slabs of equal thickness or strength. Reduced weight lowers transportation costs and saves on the cost of the material. They are typically used in the construction of upper floors in apartments/flats, commercial buildings and larger houses. Milbank hollowcore floors are available in 150mm, 200mm and 250mm deep units.
There are many benefits to using a beam & block flooring system - it is fast, cheap, and simple to install with no special skills required. Our concrete beams come in 155mm and 225mm deep prestressed options and are available in lengths of 1-6m in 50mm increments. By varying the concrete beam centres during construction, this kind of concrete flooring offers a quick and economical solution for a wide range of problems both at ground and upper floor levels.
WarmFloor Pro Insulated Flooring
WarmFloor Pro offers homebuilders a simple and cost-effective solution to quickly construct a thermally insulated ground floor, providing reduced initial construction costs and lowering heating costs, making a compelling alternative to a standard beam and block floor.
The floor is easily assembled using lightweight expanded polystyrene (EPS) blocks placed between our standard Milbank pre-stressed concrete beams (either 155mm or 225mm deep) in replacement of standard concrete infill blocks and then finished with a structural concrete screed.
A+ green guide-rated and fully certified, it is proven to be a must-have addition to any new, sustainable development, where keeping heating costs low is paramount. WarmFloor Pro has already been successfully installed in thousands of new-build projects across the country, and we are well experienced in both supply only and Supply and fix requirements.
Bespoke Precast Concrete Products
Milbank manufactures a wide variety of bespoke precast concrete components, up to 15 tonnes, in our modern purpose-built factories. We work together with clients from industries including Commercial and Residential Construction, Rail, Health, Energy, Environmental and Public Sector to name but a few. Whatever industry you work in, we’re confident that we can provide the bespoke precast concrete products you need as a solution to many common problems.
Milbank offers a range of precast concrete balcony types to suit your project requirements. All our balconies are designed by our in-house design team and manufactured, delivered and installed to the highest standards. When designing the precast concrete floors for a project, Milbank will take into consideration the design of the balconies, providing a complete package solution.
Spiral, Curved & Helical Stairs by Kallisto
As part of Milbank Concrete Products, Kallisto Stairs expertise has been commissioned for staircase installations in some of the most prestigious venues in the UK. Working with architects, engineers, and designers, we have achieved stunning, durable, precast spiral staircase installations. Today, the versatility of precast concrete, together with innovative engineering and finishing processes, allow us to create bespoke spiral staircases that are both visually pleasing and exceptionally resilient. Utilising leading Northern European manufacturing technology, our palletised formwork and precast shuttering system ensures the finish is of the highest quality.
Milbank are specialists in precast concrete stair and landing design, manufacture, and installation. With an experienced team and a dedicated production facility, we produce both simple and standard flights as well as complex bespoke units to meet your exact requirements. We take great pride in offering full-package solutions that save time, reduce costs and increase the build time of your project.
Milbank Ground Beams provide a great alternative to traditional foundations, and we manufacture specific ground beams for a number of leading contractors. Ground beams are designed to support brick or block work and steel frames and can be used to form a permanent shutter to the edge of an in-situ concrete floor slab. They are generally square or rectangular in section however, notches, sloping faces, and end details can also be incorporated.
Most modern stadia are constructed using steel structures with precast concrete elements to form the terracing, walling, stairs, and circulation areas. Concrete frame structures comprising beams, columns, walls, floors, stairs, and terracing can be used for a wide variety of applications including multi-storey car parks, retail and leisure developments, offices, schools, hospitals, cinemas, theatres etc. These structures can be built entirely from precast concrete but more commonly will be of hybrid construction comprising in-situ concrete or steel elements together with precast components.
Our coastline is valuable for both economic and social reasons, but it is a varying environment that naturally evolves through coastal erosion and flooding processes. Whether the requirement is complete wave walls or copings to refurbish existing defences, Milbank provide high-quality precast concrete blocks to resist natural processes such as wave action and sediment movement. We also work closely with the Environment Agency in supplying Canewdon blocks which are often laid in grid formation at the toe of the sea wall.
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Further technical information, image galleries and product specifications are available through the Milbank Precast Concrete website or via the BPi Download Library.
Milbank - A Sustainable Solution to the UK’s Social Housing Needs
A Sustainable Solution to the UK’s Social Housing Needs Whilst Embracing Green Principles And Reducing Fuel Poverty
With the ongoing demand for social housing in the UK, the need for sustainable, energy-efficient solutions has never been more pressing.
As housing associations and developers strive to meet the growing demand for affordable housing, they face the challenge of adhering to stringent regulations while ensuring the wellbeing of residents.
On the one hand, the demand for social housing in the UK remains a pressing issue, with thousands of individuals and families awaiting suitable accommodation. According to recent statistics from Shelter, a leading housing charity, over 1.1 million households were on waiting lists for social housing in England in 2022, highlighting the scale of the housing crisis. In Scotland, the situation is equally critical, with approximately 174,000 households registered on waiting lists. As a result, the building of new homes must accelerate in order to meet this demand.
On the other hand, over the past decade, home building has undergone a sustainable evolution, driven by a growing awareness of environmental issues and the urgent need to mitigate the impact we are having on the planet. The climate emergency is an issue which is affecting all areas of the construction sector and finding effective ways to reduce our carbon impact not only helps to tackle the issue, but it can also go a long way to reducing fuel poverty. The National Housing Federation suggests that 15% of fuel poor households in England live in social housing and with the cost of living crisis deepening, this is a problem which isn’t going away.
How can construction in the social housing sector become more sustainable?
The sustainable shift has seen significant changes in material innovation and construction techniques, with a strong focus on eco-friendly solutions. One of the most notable shifts in sustainable home building over the last decade has been the widespread adoption of green building standards and certifications. Entities like BREEAM (Building Research Establishment Environmental Assessment Method) and Passivhaus have gained prominence, guiding construction practices towards sustainability by prioritising factors such as energy efficiency, resource conservation, and reduced carbon emissions.
However, this has meant that the social housing sector has had to adapt its practices to keep pace with the changing landscape whilst juggling the ever-growing need for developing new homes. One of the key challenges facing sustainable home building within the social housing sector has been finding cost effective materials and solutions that are both environmentally friendly and durable – looking at the way a building is insulated is a major factor in driving greener practices.
The current Part L building regulations in the UK state that the U-values, or thermal transmittance, of new builds should be 0.11 W/m²K for roofs, 0.18 W/m²K for walls and 0.13 W/m²K for floors. Whilst the Passivhaus movement requires buildings to achieve a specified U-value of around 0.10W/m²K and no higher than 0.15W/m²K. Meeting these standards is a key consideration for developers.
It’s a fact that 10%-20% of a building’s heat can be lost through uninsulated floors, whilst the Energy Savings Trust has estimated that £40-£65 per year could be saved per household through the installation of effective floor insulation.
WarmFloor Pro provides a eco-friendly option
At Milbank Concrete Products, we’re proud to be a leading innovator in precast concrete products, supplying both the social and private sectors. Over the years, we’ve witnessed first-hand how the sector shifted towards a more sustainable focus, and we’ve adapted our offering to reflect this.
One example is our WarmFloor Pro solution. With its exceptional U-value rating of just 0.08 W/m²K, WarmFloor Pro not only meets but exceeds the stringent requirements of both Part L and Passivhaus standards.
What is WarmFloor Pro?
WarmFloor Pro works by replacing standard concrete infill blocks with a combination of rigid insulation modules manufactured from lightweight closed cell expanded polystyrene. These are placed in between our pre stressed concrete beams and finished with an EPS top sheet, damp proof membrane and structural concrete topping. The materials used in its manufacture are 100% recyclable, further adding to the product’s green benefits.
As an alternative to traditional beam and block floor, WarmFloor Pro provides many additional benefits alongside its eco credentials. It is simple to install and provides cost savings of around 20% to developers. Plus, with delivery direct to site, projects can proceed within a timely manner, without the delays which can sometimes be associated with more traditional methods. Both massive ticks when budgets are stretched and timelines are tight.
This innovative solution offers a sustainable alternative for social housing developments, providing superior insulation properties that contribute to reducing energy consumption and combating fuel poverty.
By incorporating WarmFloor Pro into social housing projects, developers can achieve significant energy savings while simultaneously improving the thermal comfort of residents. The durability and longevity of precast concrete products like WarmFloor Pro ensure that these sustainable benefits are realised over the long term, making it a wise investment for the future of social housing in the UK.
To find out more about how WarmFloor Pro could support your sustainability goals, speak with one of our experts by emailing estimating@milbank.co.uk or giving us a call on 01787 223931.
Written by: Lee Cowen, Managing Director Milbank Concrete Products
17/04/2024
How The Use of Precast Concrete Can Achieve Faster Build Times Whilst Helping To Plug
How The Use of Precast Concrete Can Achieve Faster Build Times Whilst Helping To Plug The Skills Shortage Gap
As the MD of Milbank Concrete Products, I am often at the front line when it comes to challenges which are facing the construction industry as a whole.
Whether it be the drop in demand for private sector building, or the adoption of sustainable and green practices within the industry, the sector is frequently dealing with ever changing needs and requirements.
However, one challenge which doesn’t seem to be going away is a skills shortage. This long term issue isn’t something which can be fixed overnight – a shift in mindset, perception and working practices needs to be achieved and this will take time.
As a leading supplier to the industry, we’re committed to providing innovative solutions to our clients, and I believe that the use of precast concrete could help alleviate some of the pressures associated with the skills shortage we’re facing here in the UK.
The Skills Shortage in the UK Construction Sector
The UK construction industry is facing a significant skills shortage, with a growing gap between the demand for skilled workers and the available workforce. Despite the size of the sector, around 200,000 skilled workers are required to close the construction skills gap by 2025 – believed to be the highest skills shortage in the sector since 2007[1]. There continues to be a growing demand for new homes, infrastructure projects, and commercial developments. However, the industry is struggling to attract and retain talent, with factors such as an aging workforce (20% of construction workers in their 50s), lack of vocational training opportunities, and negative perceptions of construction careers contributing to the shortfall.
This skills shortage poses a formidable challenge for construction companies, as it impacts project timelines, productivity, and overall industry growth. With fewer skilled workers available to fill key roles on construction sites, projects often face delays and cost overruns, jeopardising the completion of a project. Additionally, the skills gap exacerbates existing challenges within the industry, such as labour productivity, innovation adoption, and safety performance. In order to address this issue, construction companies must explore innovative solutions that optimise efficiency, reduce reliance on manual labour, and accelerate project delivery.
But what can we do to help ease the pressure of the skills shortage in the short term? Reviewing working practices and traditional building methods and materials could be one solution to ease some of the demand and have a positive impact on the skills shortage issue. Over time with new ways of working and more streamlined operations, we could see a dent being made on the amount of labour / manpower required on the ground construction projects.
The Role of Precast Concrete in Achieving Faster Build Times
Precast concrete is a revolutionary construction material that offers a solution to the challenges of the skills shortage while simultaneously enhancing project efficiency and productivity.
Unlike traditional cast-in-place concrete, which requires extensive on-site labour and curing time, precast concrete components are manufactured off-site in a controlled factory environment. This off-site fabrication process offers several advantages that contribute to faster build times and reduced reliance on manual labour.
One of the primary benefits of precast concrete is its efficiency in construction processes. By prefabricating components such as Hollowcore flooring, Beam & Block systems, precast concrete columns, and retaining walls off-site, construction companies can significantly accelerate project timelines. Off-site fabrication eliminates the need for on-site curing time, weather-dependent construction activities, and complex coordination of multiple trades, allowing construction teams to install precast elements quickly and efficiently. At Milbank Concrete Products, we leverage advanced manufacturing techniques and state-of-the-art facilities to produce high-quality precast solutions that meet the stringent demands of modern construction projects.
Precast concrete also offers inherent durability, consistency, and quality assurance, making it an ideal choice for construction applications of all scales and complexities. By standardising production processes and implementing rigorous quality control measures, construction companies can mitigate the risks associated with variable skill levels among on-site workers. With precast concrete, there’s no compromise on quality or performance, ensuring that projects are built to last and withstand the test of time.
How Precast Concrete Can Help Plug the Gap in the Skills Shortage
One of the most compelling advantages of precast concrete is its ability to reduce the reliance on manual labour on construction sites.
By shifting the fabrication of construction elements from the field to the factory, construction companies can optimise labour resources, minimise on-site workforce requirements, and improve overall productivity. With precast concrete, skilled workers are tasked with precision manufacturing and quality assurance in controlled environments, rather than performing labour-intensive tasks on-site.
The use of precast concrete presents a compelling solution to the challenges posed by the skills shortage in the UK construction sector. By leveraging off-site fabrication, standardised production processes, and advanced manufacturing techniques, construction companies can achieve faster build times, enhance project efficiency, and reduce reliance on manual labour.
At Milbank Concrete Products, we’re committed to driving innovation and efficiency in the construction industry through our wide range of precast solutions. This goes hand in hand with our commitment to becoming the most sustainable manufacturer of precast concrete in the UK. Our aim is to be net-zero for scope 1 and 2 emissions by 2030 – 20 years ahead of government targets. Through the implementation of initiatives such as introducing solar panels at our factory, moving our vehicles to HVO fuel and using a carbon neutral biomass boiler for concrete curing, we’re well on the way to achieving this.
We believe that our precast concrete could help build a brighter future for the construction sector and bridge the gap in the skills shortage, one project at a time.
If you’re interested in finding out more about precast concrete and how our products could support your project, get in touch with our experts today by emailing estimating@milbank.co.uk or giving us a call on 01787 223931.
Written by: Lee Cowen, Managing Director Milbank Concrete Products
16/05/2024
