The engineered flooring industry is growing fast. Historically, Palgrave Brown sold Trus Joist engineered flooring solutions off the back of roof truss orders, selling to our large existing customer base of predominantly national housebuilders. Today, national housebuilders still account for around 85% of the company’s engineered floor sales, but as customer awareness and confidence grow, the market is opening up to everyone, including merchants, timber frame specialists, regional and small to medium housebuilders. About 10% of the enquiries we receive are from builders merchants. The large merchant chains now have an I-joist offering, and smaller merchants represent a small but growing part of Palgrave Brown’s business.

Although customers can still pick up standard length traditional timber floor joists from their local merchants, many architects and engineers are now specifying more complex flooring designs that require longer, higher performing engineered joists.

More builders are looking for the increased performance and installation advantages offered by I-joist engineered floors. For example, there are fewer components to install, simple Part E and Part L Regulation solutions and a lifetime guarantee.

Unlike traditional timber, TJI joists are available ex stock in lengths of up to 15m, so instead of having to install three, 5m joists, customers can install one continuous beam that uses the available support to span the floor’s entire length. This significantly reduces time on site and increases the floor’s rigidity by using back span and eliminating laps over beams and walls.

I-joists are becoming increasingly popular with regional and small to medium housebuilders as the product is tried and tested and they can see the larger companies using them on a regular basis.

Alternative flooring system

Recently Palgrave Brown expanded its manufacturing capacity for Posi-Joist, an alternative flooring system that appeals to a different market. Unlike TJI, Posi-Joists don’t offer the squeak-free guarantee but they do allow for the easy installation of cables, pipes and services and over the years the product has built up a loyal following.

Its open web design enables electricians and plumbers to complete on site quickly and neatly and it can span greater distances than alternative timber products. Its full potential has yet to be realised as it’s still relatively new in the market.

Palgrave Brown is also looking at a variety of new flooring alternatives and is keeping a close eye on new products and innovations. At present its focus is on flooring solutions for first and upper floor levels but it is looking at ways to increase floor installations at ground level and within apartments and multi-occupancy buildings.

One of the biggest competitors for EWP in these sectors is concrete. But it is affected by supply problems and extended lead times, so we are looking at ways of coming up with solutions. The main resistance to supplying I-joists instead of concrete is historical. We have to break down the barriers of tradition and make sure customers get the product they want.

Easy handling

With I-joists you don’t need to use a crane to lift the product onto site – they’re lighter and don’t require mechanical handling, although they need proper ventilation detailing.

But there need to be better solutions for the ground floor and apartment sectors. About 41% of all new homes are flats and they tend to have concrete floors.

There are a lot of flats built with I-joist floors in timber frame developments but when it comes to traditional masonry construction there needs to be a robust model. We must make the product a lot more accessible and easier for contractors to use and specify. Customer confidence in the industry is high and most builders are happy with the products on offer but some have concerns about lead times. Unlike traditional joists, engineered flooring solutions have to be designed according to individual requirements and Palgrave Brown has 11 Trus Joist designers working in house.

In the past, delivery of long length joists was a problem but builders and specifiers are all conscious of the dimensions used now and at Palgrave Brown we’ve worked with haulage contractors to provide solutions. We work with supply partners on product development too, to keep customers updated on changes to regulations and new system solutions.

Recently Posi-Joist was also certified under the Programme for the Endorsement of Forest Certification schemes, making it easier for customers to gain EcoHomes credits.