Beam and block flooring is a widely recognized construction method that offers a durable, stable, and reliable foundation for various types of buildings. This technique involves placing a series of T-shaped beams parallel to each other on top of supporting blockwork walls, with infill blocks placed between the beams to create a solid floor structure. The resulting system is known for its strength, ease of installation, and ability to support heavy loads, making it a popular choice for residential and commercial construction projects.
The beam and block system is particularly favored for its ability to provide a level and stable surface without the common issues associated with traditional flooring methods—such as creaking, shrinking, or bouncing. This makes it an ideal solution for both new builds and renovations. Additionally, the system allows for the incorporation of essential services, such as plumbing and electrical wiring, within the cavity formed by the beams and blocks. This not only streamlines the installation process but also enhances the functionality of the finished structure.
To ensure a successful installation, it is crucial to follow a structured and methodical approach. This includes proper planning, adherence to safety guidelines, and the use of appropriate materials and tools. The following sections outline the key steps and considerations involved in installing a beam and block floor system, based on the information provided in the source documents.
Preparing for Installation
Before beginning the installation of a beam and block floor system, it is essential to conduct thorough planning and site preparation. This includes reviewing the design specifications provided by the Beam office or the project architect, identifying the correct start points for beam placement, and ensuring that all necessary materials are available on-site.
One of the first steps in the preparation process is to verify that the substructure walls are suitable for supporting the beams. A 100mm nominal bearing is required on the beams at each end based on brickwork substructures. This ensures that the beams are properly supported and can bear the intended load without compromising the structural integrity of the building. Additionally, the substructure walls should be prepared for slipbricks, which are used to secure the beams in place and provide additional stability to the floor system.
If mechanical plant is being used to lift and position the beams, it is important to ensure that the lifting equipment is appropriate for the task. Lifting points should be located within 300mm of each end of the beam to minimize the risk of damage during installation. For manual labor, the correct personal protective equipment (PPE) must be used to prevent injury, particularly to the hands, which are most at risk during the handling of beams and blocks.
A risk assessment and method statement should also be carried out by a competent person prior to the start of the installation. This document should outline the potential hazards associated with the project and the measures that will be taken to mitigate these risks. If any uncertainties arise during the installation process, it is recommended to contact the sales office for further guidance and support.
Installing the Beams and Infill Blocks
The installation process begins with the placement of the T-shaped beams on top of the supporting blockwork walls. These beams are typically made of reinforced concrete and are designed to span the distance between the walls while providing a sturdy base for the infill blocks. The beams are positioned parallel to each other, with the correct spacing determined by the design specifications.
To ensure proper alignment, infill blocks are used as spacers at either end of the beams. These blocks help maintain the correct distance between the beams and prevent them from shifting during installation. Once the spacers are in place, the remaining infill blocks can be dropped into position as required. These blocks are usually made of lightweight concrete or other suitable materials and are designed to fit snugly between the beams, forming a solid and stable floor.
In some cases, it may be necessary to trim or cut the infill blocks to accommodate protruding drainage pipes, electrical conduits, or other services. This requires careful planning and precise measurements to ensure that the modifications do not compromise the structural integrity of the floor system. Similarly, the blocks may need to be cut to fit around corners or other irregularities in the substructure.
Once the beams and infill blocks are in place, the next step is to prepare the substructure walls for slipbricks. These are small concrete blocks that are placed at specific intervals along the substructure walls to provide additional support and stability to the beam and block system. The slipbricks are typically positioned at the ends of the beams and along a block strip that runs along the substructure wall. This helps distribute the load more evenly and prevents any potential movement or shifting of the beams.
Completing the Wet Works
After the beams and infill blocks have been installed, the final step in the beam and block floor system is the completion of the wet works. This involves the application of a standard brick mortar to bed the slipbricks in place and ensure that they are securely attached to the substructure walls. The mortar should be mixed according to the manufacturer's specifications to ensure the correct consistency and strength.
The slipbrick locations are typically indicated on the design drawings provided by the Beam office or the project architect. These locations are strategically chosen to provide maximum support and stability to the beam and block system. Once the mortar has been applied, the slipbricks are carefully placed in their designated positions and pressed firmly into the mortar to ensure a secure bond.
In addition to the slipbricks, the wet works may also involve the application of a layer of render or plaster to the surface of the floor system. This not only provides a finished appearance but also helps to seal the structure and protect it from moisture and other environmental factors. The render should be applied evenly and allowed to cure according to the manufacturer's recommendations before any further work is carried out.
Safety and Quality Considerations
Throughout the installation process, it is essential to prioritize safety and quality. This includes ensuring that all workers are properly trained and equipped with the necessary PPE, particularly when handling heavy beams and blocks. Additionally, all lifting operations should be carried out by qualified personnel using appropriate equipment to minimize the risk of injury or damage.
Quality control is also a critical aspect of the installation process. This involves regularly inspecting the beams and infill blocks for any signs of damage or defects before they are placed in position. Any damaged materials should be replaced immediately to ensure the structural integrity of the floor system. Similarly, the alignment and spacing of the beams should be checked periodically to ensure that they are correctly positioned according to the design specifications.
Conclusion
Beam and block flooring is a reliable and efficient construction method that offers a stable and durable foundation for a wide range of building projects. By following a structured and methodical approach to installation, builders and DIY enthusiasts can ensure a successful and long-lasting result. From the initial planning stages to the completion of the wet works, each step in the process plays a crucial role in the overall performance and longevity of the floor system.
Whether you are a professional builder or a DIY enthusiast, understanding the key considerations and best practices involved in beam and block floor installation is essential for achieving a high-quality finish. By adhering to the guidelines outlined in this article and using the resources provided by the manufacturer, you can confidently undertake your beam and block flooring project with the assurance that it will meet the required standards and specifications.