Op-deck is a lightweight insulated floor system. The advantages of composite metal deck concrete floors and traditional rib floors have been combined in this unique patented flooring system.

This insulated concrete floor system (ICF) is based on traditional concrete installation but with optimal design and installation flexibility.

It is suited to insulated, high-load-bearing applications including car park roofs, intensive green-roofs and suspended high load floors including supermarkets, hospitals, etc.

An Op-deck floor can be laid on supporting structures of steel, concrete, brickwork, wood, etc. The Op-deck sandwich floor panels function as permanent shuttering for a relatively thin reinforced concrete floor with a free span of up to 10 metres maximum.

Op-deck comprises a sandwich panel made from thin profiled steel sheets with PIR foam insulation. EPS profile blocks on the sandwich panel ensure further weight reduction and turn the floor into a concrete floor of the T-beam principle (concrete rib floor).

Both components, the sandwich panels and the EPS profile blocks are installed on site. The result, after the reinforcement and concrete have been applied, is a lightweight insulated concrete floor with a large free span, small constructional height and a smooth white (RAL 9002) underside of flat sheeting, which functions as a ceiling. It is possible to include under floor heating or a complete energy management system in the Op-Deck insulated concrete floor.

SONY DSC
Op-Deck Insulated Roof System

The Op-Deck System:

  • Thickness of finished concrete floor from 250 mm.
  • Low own weight (from 190 kg/m2).
  • Free span up to 10m.
  • High permissible load (Prep).
  • High bearing capacity at point load (Prep).
  • Flexible system construction.
  • Fire-resistant (Resistance to Fire Penetration and Fire Transfer) = 60 minutes.
  • Insulating floor (Rc > 4 [m2.K/W]).
  • Strut-free installation (max. 5.5m).
  • Simple and fast installation.
  • Easy logistics at the building site.

Op-deck sandwich floor panels and the EPS profile blocks are simple to process. An installation procedure is available. Optionally specialized application companies are available to install the Op-deck insulated concrete floors.

CDI OP-Deck Brochure

If you have any questions regarding the system please contact our technical team.

"Using Op-Deck meant that we could incorporate a car park on the roof of the store as we were struggling for space to hit the planning requirements on the ground"

Tom Parsons

Op-Deck sandwich floor panels and EPS profiled insulation blocks are quite simple to install, the fixing details are available on request. If required we can arrange installation through a nominated specialist contractor.

Op-Deck design software has been specially developed for the system to provide details of the optimum cross section based upon performance and design details provided by the client. As well as providing a load bearing structural floor Op-Deck provides up to a 60% reduction in weight against other floor systems. As a result the total cost of a project can be reduced considerably.

Case Studies

Self Build & Renovations

FAQs

Ask CDI a Question

  • Q

    Do I keep my joist centres at 400mm when using Lewis Deck?

    A

    One of the great things about using Lewis Deck is that it opens up a number of different options for you and one of them is around joist centres you can work with.

    Traditionally we see the vast majority of architects and designers insisting that timber joists be installed at either 400mm or at most 600mm because this is the limit of what timber floor systems will effectively span to. Now with Lewis, because of its unique profile (with the dovetails dimensions) and the way it interacts with the thin (50mm) screed laid on it, you can actually go much wider than these figures. With a 50mm screed, on top of the sheets, Lewis allows you to have unpropped centres of up to 1200mm (1.2m). Even at these much wider centres Lewis will allow you to have a permissible load of 14.8kN/m2, which in English is just under 1.5 Tonnes per m2. Now this might sound fantastic, and it is, but in reality for 95% of new build homes this figure won't really make too much difference to what you were planning on doing with upstairs. What it does mean though is that at your normal centres, of approximately 600mm, your floor becomes so much stronger than traditional forms of floor structure that it allows you to do things on the 1st floor that you take for granted on the ground floor. First of all is the obvious one, you get a solid floor, meaning no more squeaky floor boards or hearing people walking around upstairs and knowing exactly where they are up there! Having the solid floor gives you the chance to have a very efficient underfloor heating system (see our applications section for more details) which in most cases will probably mean a slight reduction in your fuel bills. Other big benefits of having a stronger floor upstairs include being able to have either thinner tiles or much heavier tiles than you can use on timber floor systems. The screed and Lewis working together pretty much stops any deflection in the floor meaning that these types of tiles won't crack or move and lift over time as the floor doesn't move or deflect! So in conclusion yes you can have much wider joist centres than the 400mm centres that you normally see on new developments but even if you wanted to keep them the same by using Lewis Deck it opens up so many benefits that you just aren't able to incorporate with traditional timber floor systems.

    Q

    Do you fix Lewis Deck down to the joists?

    A

    The short answer to this is no Lewis Deck doesn't have to be fixed down.

    Generally the reason why people choose to use Lewis Deck over more traditional floor systems is that they are looking to enhance the upper floor that they are working on. So if you are going to be looking at using Lewis then you might as well look to incorporate its full range of benefits. One of which is the major uplift in acoustic performance that you get from using the system. Getting the best results, acoustically, is achieved by laying the floor as a floating floor. This then creates separation between the supporting floor joists and and the steel deck. To enhance this further introduce a resilient strip on top of the joist. See below. [caption id="attachment_559" align="alignnone" width="300"]Lewis Metal Dovetailed Sheeting Deck with acoustic Sylomer resilient strips Lewis Metal Dovetailed Sheeting Deck with acoustic Sylomer resilient strips[/caption] When it comes to determining which of our acoustic resilient strips to use (because we have a few of them and they all do different jobs depending on the use of them and the type of structure below) we are happy to help you come up with the correct option that suits your project the best. A standard Lewis Deck floor detail (such as the detail above) easily achieves UK requirements for acoustic (as well as fire) resistance for residential separating floors. Higher performance standards are easily achievable too. Because of this we have seen Lewis Deck used frequently in in bespoke projects such as live music/ theatre venues, cinemas, recording studios, specialist test labs, plant room floors and many other commercial applications. Also as well improving improving the noise reduction between floors by not having to fix the sheets down you are massively speeding up the installation process!! Having to spend less time on site could have a positive knock on effect on the cost of your project. Please feel free to give us a call and discuss this further should you wish to do so.

    Q

    Lacomet – How come it has no scrap value?

    A

    Lacomet – How come it has no scrap value? Many of the projects that we get involved in starts with a phone call or email to us from someone researching replacing stolen leadwork. Many of these are old buildings, such as schools or churches, where this isn’t the first time that the lead has been stolen and they call us fed up with having to replace it again full in the knowledge that they will more than likely go through the same problem once more in the near future if they continue to use lead. One of the big benefits that Lacomet FL brings to a project is the fact that it has no scrap value and therefore the chances of it being stolen are massively reduced. Due to the 2 thin aluminium layers, and its five layer total construction, it is of no value to thieves. Lacomet can be recycled but the polyester based coating would need to be de-laminated first and the amount of recovered aluminum is then very low, in fact it would be easier and more profitable to collect empty drinks cans than to mess about stripping Lacomet down. We can also supply stickers that can be placed in strategic locations informing people that what is now on the roof is not lead and that it has no scrap value.

  • Q

    Do you fix Lewis Deck down to the joists?

    A

    The short answer to this is no Lewis Deck doesn't have to be fixed down.

    Generally the reason why people choose to use Lewis Deck over more traditional floor systems is that they are looking to enhance the upper floor that they are working on. So if you are going to be looking at using Lewis then you might as well look to incorporate its full range of benefits. One of which is the major uplift in acoustic performance that you get from using the system. Getting the best results, acoustically, is achieved by laying the floor as a floating floor. This then creates separation between the supporting floor joists and and the steel deck. To enhance this further introduce a resilient strip on top of the joist. See below. [caption id="attachment_559" align="alignnone" width="300"]Lewis Metal Dovetailed Sheeting Deck with acoustic Sylomer resilient strips Lewis Metal Dovetailed Sheeting Deck with acoustic Sylomer resilient strips[/caption] When it comes to determining which of our acoustic resilient strips to use (because we have a few of them and they all do different jobs depending on the use of them and the type of structure below) we are happy to help you come up with the correct option that suits your project the best. A standard Lewis Deck floor detail (such as the detail above) easily achieves UK requirements for acoustic (as well as fire) resistance for residential separating floors. Higher performance standards are easily achievable too. Because of this we have seen Lewis Deck used frequently in in bespoke projects such as live music/ theatre venues, cinemas, recording studios, specialist test labs, plant room floors and many other commercial applications. Also as well improving improving the noise reduction between floors by not having to fix the sheets down you are massively speeding up the installation process!! Having to spend less time on site could have a positive knock on effect on the cost of your project. Please feel free to give us a call and discuss this further should you wish to do so.

    Q

    Lacomet – How come it has no scrap value?

    A

    Lacomet – How come it has no scrap value? Many of the projects that we get involved in starts with a phone call or email to us from someone researching replacing stolen leadwork. Many of these are old buildings, such as schools or churches, where this isn’t the first time that the lead has been stolen and they call us fed up with having to replace it again full in the knowledge that they will more than likely go through the same problem once more in the near future if they continue to use lead. One of the big benefits that Lacomet FL brings to a project is the fact that it has no scrap value and therefore the chances of it being stolen are massively reduced. Due to the 2 thin aluminium layers, and its five layer total construction, it is of no value to thieves. Lacomet can be recycled but the polyester based coating would need to be de-laminated first and the amount of recovered aluminum is then very low, in fact it would be easier and more profitable to collect empty drinks cans than to mess about stripping Lacomet down. We can also supply stickers that can be placed in strategic locations informing people that what is now on the roof is not lead and that it has no scrap value.

Ask CDI a Question

Latest Blog

CDI 2017

Granite tiles and shower tray laid over a Lewis Deck and Concrete floor upstairs over timber joists

Travertine wetroom by Craig Bills

30th May 2017

Craig Bills is a master tiler and has been installing wet-rooms using Lewis Deck and concrete for over 20 years, he is a passionate advocate for the Lewis Deck system in wet-rooms and bathrooms as it give an opportunity for the floor to be 1 piece of waterproofed concrete.  This makes a very robust and …

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We've a new model down at Swindon!

18th May 2017

One of the great benefits that you get from introducing Lewis Deck into a residential development is the option to install a wet room floor into bathroom/ en-suite areas with extreme ease compared to other flooring systems as well as maintaining one solid concrete slab in the room reducing the possibility of leaks from a …

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