AB Building Products Ltd

LocationA penthouse terrace in Brompton Road, Knightsbridge, required a decking system that complied with Class A fire rating regulations. The existing timber deck, which was mounted onto timber bearers, had been removed, revealing a complex roof structure with multiple levels and a series of upstands, likely serving as column supports from the structural walls below.The ProblemThe challenge was to construct a secure substructure over the irregular roof deck while maintaining a consistent, level surface suitable for decking installation. Due to the varying height thresholds across the terrace, the solution needed to accommodate both extremely low and high points while ensuring structural stability. Additionally, the owner wanted to lay the decking diagonally to the building, requiring precise alignment of the supporting structure. It was also imperative that current fire regulations were met for terraces, requiring Class A1 Fire Rated substructure and decking. The SolutionTo achieve a stable substructure, Wallbarn MetalPad D adjustable height pedestals were installed with Wallbarn aluminium rails/joists, incorporating both Box Rails and I-Plus beams to accommodate height variations. Where thresholds were minimal, 20mm Box Rails were used with the lowest-height pedestals, whereas higher areas required 100mm I-Plus Beams, doubled up and mounted onto larger MetalPad D pedestals. This approach ensured a level surface across the entire terrace.The Exadeck ceramic decking boards were installed on a diagonal plane, so the top layer of the aluminium rails needed to be fixed at the same angle to allow the decking fixing clips to be mounted at right angles to the rails. Connector brackets were used at joining points to enhance structural strength. The Exadeck boards, designed with a side milling profile, were secured using hidden wing clips, ensuring a uniform gap between boards for efficient drainage.Thanks to the precision manufacturing of Exadeck porcelain, rectified edges provided perfectly straight lines, eliminating the risk of warping or inconsistent board thickness. Using Exadeck allowed the team to cut precisely, to achieve sharp, clean lines effortlessly and overcome challenging detailing constraints. The result was a stunning, fire-compliant decked terrace with a clean, modern, and natural-looking finish, overcoming complex structural challenges while adhering to the highest fire safety standards.

The LocationEasy Quay House is a sought-after modern residential and commercial development situated in a prime coastal location on the eastern quay in Sutton Harbour. Positioned next to the marina, the property offers stunning views and contemporary architectural design. The development is subject to challenging weather conditions due to its proximity to the sea, necessitating durable and weather-resistant materials for long-term performance. The building comprises of a part 10-storey, part 5-storey, mixed-use premises, with commercial offices at ground floor level and 56 self-contained residential apartments above. The ProblemAs a multi-use development featuring balconies and terraces, Easy Quay House required a decking solution that met strict fire safety regulations while also being resistant to the harsh marine environment. The chosen decking material needed to be non-combustible, weatherproof, and durable to withstand exposure to saltwater, wind, and UV rays, while maintaining an attractive aesthetic.Following an examination by Bailey Partnership, combustible materials were found in the external wall systems, and subsequently, the cladding was removed. The works included recladding, with the addition of external wall insulation; removal of plywood sheathing boards and replacement with non-combustible materials; and insertion of suitable cavity barriers at all horizontal and vertical party wall junctions and around all windows. The render was kept white, and the overall facade retained the original features and appearance where possible. The cladding replacement works included remedial works to the combustible components of the balconies. With this in mind, it was imperative that the decking chosen was A1 Fire Rated and in keeping with the original building. The SolutionAlu Installations completed the building works, opting for CDECK in Silk Grey, a premium fibre cement decking specifically designed for balconies and high-rise applications. With its A1 fire rating, CDECK fully complies with fire safety regulations, ensuring peace of mind for residents and property managers. Additionally, its durable weatherproof composition makes it an ideal choice for coastal environments, offering long-term resistance to moisture, salt, and temperature fluctuations. The elegant Silk Grey finish provides a soft modern and sophisticated look, blending seamlessly with the architectural design of Easy Quay House while delivering exceptional durability and safety.

The LocationNorfolk House, located at 31 St James's Square, is an office development in the St James's area of London SW1. The L-shaped, landlocked site is bordered by Waterloo Place to the east, St James's Square to the west, Charles II Street to the north, and Pall Mall to the south.HistoryNorfolk House is steeped in history: a collection of buildings in London were originally called Norfolk House, as the collective London residences of the Howard family, headed by the Dukes of Norfolk.31 St James's Square, Westminster, was built between 1748-1752 for Edward Howard, 9th Duke of Norfolk, designed by Matthew Brettingham (1699-1769), "the Elder". This building was demolished in 1938. The subsequent office block was used during WW2 and was fully refitted until it no longer met modern requirements.In 2019, the office block was demolished and replaced, with reconstruction of 31 St James Square and 30 Charles II Street neo-Georgian classical-style facades.The redevelopment of Norfolk House comprised the creation of a new 8-storey, commercial office building, including the reconstruction of two brick and Portland Stone facades. The project also involved additional excavation to create a deeper basement. Ref no 16/09591/FULL.ProblemA key factor in the decision-making process was retaining the character and appearance of the St James's Conservation Area while meeting current fire regulations and standards. SolutionCDECK has an authentic, rustic finish, with deep embossed texture mimicking real timber decking, with wide and long boards, suitable for covering large areas. With the A1 Fire Rating, CDECK surpassed the requirements with its durability and technical specifications, blending sympathetically with the environment.

At the Pirbright Army Training Centre, the officer’s mess terrace, a central hub for gatherings, underwent a significant transformation with the installation of CDECK Fire-Rated Fibre Cement Decking. This project replaced outdated timber decking with a Quartz Grey finish, addressing both aesthetic and functional challenges.The existing timber decking, likely compromised by years of wear and exposure to the elements, posed safety risks and demanded frequent maintenance. Recognising the need for a more durable and low-maintenance solution, the decision was made to upgrade to CDECK, a product designed to deliver the warmth and texture of wood while eliminating the drawbacks associated with traditional timber.The installation process was completed efficiently within just two days, with the old timber decking removed and replaced with the CDECK Quartz Grey system. The new decking offers several key benefits, including compliance with fire safety standards, enhanced durability, slip resistance, and comfort underfoot. These attributes make it a superior choice for high-traffic areas, ensuring the terrace remains safe, tidy, and welcoming for officers.Quartz Grey CDECK harmonised seamlessly with the traditional architectural aesthetics of the training centre, blending practicality with visual appeal. This project exemplifies how modern materials can provide a thoughtful, long-lasting solution to replace ageing infrastructure, ultimately enhancing both functionality and safety for users.