Making Ground Floors Smarter: How Milbank GDeck is Simplifying Insulated Flooring
and Part L energy standards. With rising demands for lower U-values and reduced heat loss, Milbank GDeck’s continuous insulation layer simplifies ground floor thermal design. U-values as low as 0.09 W/m²K can be achieved depending on specification, helping to cut heating demand and future- proof builds. As the insulation is built into the system’s core, there’s also less risk of cold bridging or patchy installation quality often seen with complex multi-layer floors.
The way ground floors are built has changed little in decades. But growing demands for energy efficiency, labour savings, and faster builds are now pushing the industry to rethink established methods. Traditional beam and block still dominate UK housebuilding and commercial projects, yet with tighter regulations and increasing time and cost pressures, innovative solutions are emerging.
One example is Milbank GDeck, a new precast insulated flooring system by Milbank Concrete Products. Designed to simplify ground floor construction, improve build quality, and support energy targets, it refines the familiar beam approach many contractors already trust – making it faster and smarter without a radical overhaul.
A familiar principle, refined At its heart, Milbank GDeck still relies on prestressed concrete T-beams spanning ground floor areas. The difference lies in what fills the gaps. Instead of heavy concrete infill blocks, Milbank GDeck uses EPS (expanded polystyrene) insulation panels that provide both structural infill and a continuous thermal layer. A key innovation is the integrated top sheet, formed by the EPS infill blocks working together with the load-bearing top rail. This means the floor can be walked
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on immediately after installation, without the need for extra boarding or temporary protection. Follow-on trades can access the area sooner, sequencing improves, and there’s less disruption on site.
Designed with site efficiency in mind Installation is straightforward. Once the load-bearing walls are in place, prestressed beams are laid out following the design drawings (produced by Milbank). Lightweight EPS panels – weighing around 2kg each – then slot easily between the beams, guided by load-bearing rails on top. Supplied in standard precision moulded sizes, the panels can be quickly positioned across most of the floor area, with only minimal on-site cutting needed. This helps reduce waste and keeps the site cleaner and more organised. After the system is installed, the usual membranes, edge insulation, and structural mesh are placed directly on top before the concrete topping is poured. By streamlining these steps, Milbank GDeck helps contractors save time, reduce labour needs, and maintain safer, tidier sites – crucial on today’s busy builds.
Thermal performance without complex detailing A major advantage of insulated precast systems is how they help meet Passivhaus
Addressing sustainability at multiple levels Milbank GDeck isn’t just about faster installs and better energy performance. It also responds to the growing need to reduce embodied carbon. The system includes: • Low-carbon concrete mixes in prestressed beams, with reduced cement content. • EPS panels containing 15% recycled material, fully recyclable at end of life. • Optimised material use through prestressing, cutting total concrete volume. • Less site waste thanks to precise offsite manufacturing. Together, these measures deliver embodied carbon savings of up to 25% compared to conventional reinforced concrete floors.
Evolving ground floors – without complicating construction As new build methods evolve rapidly, Milbank GDeck offers an evolution of a proven approach. For contractors, specifiers, and developers already comfortable with beam and block systems, it provides a practical path to better site efficiency, thermal performance, and sustainability – all while keeping the simplicity and durability that have made precast concrete a mainstay of ground floor construction for years.
www.milbank.co.uk
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