Adding a Floor to an Existing Building - CDI
Adding a Floor to an Existing Building

One of the great things about Lewis Deck is its versatility when it comes to the type of building it can be installed in. This one is no exception. Here we see Lewis Deck being used to add a floor on top of an existing building in London.

Lewis Deck was chosen, on this particular project, for a number of the key benefits the system brings. These being the strength of the system with only needing a thin screed on top, the acoustic qualities & vibration control properties and the speed an ease of installation.

This project even requested much longer sheets than standard in an effort to speed up the installation process even more. In fact you can see from the main photo above that some of the sheets were extremely long. The longest being just over 6.5m.

We initially started work on the design side of this project back in 2016 and after a 2 year gap we were brought back on board in 2018 to continue the discussions regarding the deck. The order was eventually placed in early 2020 and after a delay due to the site closing down during the lockdown period we eventually delivered all of the deck in August this year.

The deck was laid on top of a steel beam/ joist structure and fixed down periodically. The joists were installed, mainly, at 400mm centres and the deck was cut to size to match these centres.



There were a few teething problems initially due to the size of some of the sheets and the tightness of the working area but as soon as those were ironed out the deck was laid without any issues and much quicker than we thought.

The Main Contractor.

Because of these extra long sheets we are asked to prepare the deck so that each bay was packed individually. This posed our factory a bit of a test to be able to pack sheets of all different sizes and get them transported to site in the smallest number of packs and vehicles as possible.

The total floor area of the project was 900m2 and this was laid in just over 2 days with the fixings taking an additional couple of days. We continued to give guidance and advice throughout the installation process and we on hand to provide the required information and documentation as was required by the site and installation teams.



Ask CDI a Question

  • Q

    What are the Lewis Deck sheet sizes?


    Q: What sheet sizes are held in stock for delivery within a few days after order? A: We stock 2500mm and 1300mm sheets.  These are all 630mm wide and 16mm deep.  Deliveries are made via the pallet network directly to site.  The smaller sheets are aimed at small bathroom renovation projects and can be supplied in small numbers via TNT. 2.5* and 1.3m sheets allow for the 100mm overlap to occur over a joist, with joist centres being either 300mm, 400mm, 600mm, 800mm*, 1200mm and 2400mm*. (*2.5m sheet only) For larger projects we are able to produce bespoke sheet sizes if required, please get in contact to discuss other options for sheet sizes.

  • Q

    Why don't my Lewis sheets interlock like they do in the video?


    Q: Why don't my sheets interlock like they do in the video? A: The sheets have two sides (one printed, one plain), the dovetails on either side are different widths, it is then necessary to alternate the sheets print up and then print down.


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Adding a Floor to an Existing Building - CDI