ICF & Hollowcore Case Study - New Dwelling in Burgh Castle, Norfolk -
ICF & Hollowcore Case Study - New Dwelling in Burgh Castle, Norfolk -
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Case Study - Burgh Castle, Norfolk

In August of this year we received a quotation request from Ian and Sharon as they had a requirement for a concrete floor to be built over the basement of a new build in Burgh Castle, Norfolk. It was immediately apparent to us from their enthusiasm that this was a personal project and that Ian and Sharon had a definite vision of the end result. As self-builders Sharon and Ian opted to use Nudura, a system for ICF (Insulated Concrete Forms).

From a technical point of view, the design that we produced was unusual, resulting from a desire to keep the costs down and the building method stress free.

Sharon has been kind enough to provide her perspective on how the project has been going in the story below:

Sharon's story - Using Insulated Concrete and hollowcore to build a dream home

“We originally wanted to just buy a building plot closer to my parents, so we could build something more suited to us.

Unfortunately, there was nothing on the market, and the land that was available had no hope of getting planning permission.

So, we decided to buy a property that was, in our opinion, past its sell buy date and uneconomical to repair.

We searched for an architect that could help us to get planning permission for a new property on the site of the soon-to-be demolished house. It was important that we found an architect that understood that we were going to carry out the bulk of the work ourselves. We eventually managed this.

After many failed idea sketches of houses from the architect we started to get disillusioned, so Ian sat and sketched a drawing showing the architect what we wanted. He worked his magic, got it through planning and so it began.

The basement was dug before Christmas, but we did not start building until end of May. But wow! It was amazing how quickly things started to come together. So far, we have just had ground workers pouring the basement slab, and everything else has been done by us, our son in law, my 81 year old Dad, (who still thinks he can do it all- they don’t make them like him anymore).”

Diy enthusiast

Nudura from ICF

“​We have always been into DIY and this was something we were confident we could do ourselves as long as we made some smart decisions. Therefore, we chose Nudura from ICF supplies as our main building material, after seeing them at the Homebuilding & Renovating Show. While at the event, we had a crash course from Alan on the stand itself which was really helpful. Consequently, we booked places on the ICF course (you have to do this, before you can buy Nudura), and here we are.

Basement built, tanked and ready for the next stage- the garage floor.”

Hollowcore planks

“Structural engineer Antony suggested we used floor planks to span the garage floors, which we were unsure of to start with, but Matthew at Floorspan was there to guide us through, and anything we were unsure of he had the answers.

We fitted the planks ourselves and they went in with no bother. Super pleased with them, so if we can use them more- we most definitely will.”

– Sharon

Hollowcore planks - Design aND SUPPLY

Sharon’s description of the project describes our challenge perfectly. We needed to create a design that could satisfy building requirements whilst remaining simple to install. Generally, this would be a straight forward process as we would suggest using beam and block for a ground floor. However, as per the architect’s brief, this was a garage floor, spanning a basement cavity. With this in mind, hollowcore planks were a much more suitable solution.

The design was further complicated by the presence of a staircase with a curved entrance. This meant that this area required additional load bearing capability. Our solution was to design and manufacture a floor from hollowcore plank by cutting  the plank diagonally. This avoided the need for a steel lintel around the stair area and increased the load bearing ability of the floor.

As already described, the floor was installed without issue and the project is still moving forward positively. Helped on by their knowledge of ICF and the provision and design of the hollowcore floor spanning the cavity. We wish Ian and Sharon all the best with the project and hope to work with them in the future. Please get in contact with us if you would like to know how hollowcore plank or beam and block floors can fit in to your self-build.

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