Material-efficient, stronger base floor solution that genuinely reduces the carbon footprint of floor construction
Due to its unique 3D structure, the FF-FLOOR solution requires 30 percent less concrete than traditional solutions, thus making similar base floor structures 20 percent stronger.
The solution, which utilizes mold technology, consists of insulation panels with lattice-like grooves. The concrete poured on top of the insulation panels with locking tongue and groove joints fills the grooves creating a lattice-like support structure for itself in the base floor. The delivery also includes a custom-made reinforcing mesh designed for the system, which is installed into the grooves in the insulation panels. This eliminates the need to walk on top of the panels at the worksite.
- Dimensions 600 x 1200 mm
- Thickness 100 and 200 mm
- Functions as both thermal insulation and casting mold
- Two-way fluting 50/60 x 50 mm k/k300 mm
- Steel brackets for mesh #300 at the grooving intersections (separate plastic reinforcing bar spacers are not required)
FF-FLOOR 100-mm concrete slab vs. traditional 100-mm concrete slab:
- Amount of concrete reduced by 30% = smaller carbon footprint
- Strength of the concrete slab increased by 20%
- Faster installation: one solid layer of insulation material + steel mesh #300
- Consumption of steel is reduced
- The concrete slab dries more quickly
- The concrete and the insulation material adhere better to each other
Traditional reinforced concrete structure
Genuine emission reductions for future construction
The Ministry of the Environment is expected to specify limits for the lifetime carbon footprint of buildings in 2023, and according to current plans, the calculation of carbon footprint will become mandatory by 2025.
The material and energy efficient FF-FLOOR solution will reduce the carbon footprint of buildings both during the construction phase and during their use, while also streamlining building projects. The reduced amount of concrete also decreases the curing time, which is often challenging in terms of scheduling at the worksite.
Finnfoam’s Managing Director Henri Nieminen emphasizes that any comparison of solutions with different carbon footprints must consider the entire life cycle of the buildings and that the comparison must be made at the building level.
“We at Finnfoam support reducing the carbon footprint with both new construction stage solutions and proper thermal insulation, which is the most significant factor in reducing use-phase emissions. After all, 70–85% of building emissions are produced during use”, says Nieminen.
Basis for structural dimensions:
Tensile reinforcement of the concrete slab (FF-FLOOR insulation in the grooves) and the overall thickness of the slab based on structural design (recommended minimum thickness of the slab 100 mm from the base of the groove).
- FF-FLOOR EPS 100S/200 mm meets the U-value requirements specified for conventional base floors
- Alternatively, insulation can also be provided using two layers of insulation, where the lower layer consists of FINNFOAM or FF-XPS 200 LATTIA/100 mm with FF-FLOOR EPS 100S/100 mm on top
- The high water vapor resistance of FINNFOAM and FF-XPS insulation products significantly improves the moisture performance of the base floor and facilitates the installation of the insulation on top of crushed stone. • The 6-mm steel reinforcements placed into the grooves receive the load of the slab
- The FF-EPS section between the two-way fluting functions as lightening for the slab
- Any drying shrinkage of the slab is secured with steel reinforcement on the top surface or fiber-reinforced concrete (latter recommended)
Attachment of underfloor heating piping:
- To the steel reinforcement on the upper surface
- When using fiber-reinforced concrete, on to the surface of the FF-EPS with plastic fasteners and tensile reinforcement where necessary.