Midlands-based Staircraft has earned a well-deserved reputation for pushing standards across the sector.
Today, the business carries forward these founding principles as it continues to manufacture high-quality floor kits, I-joist staircases and door kits. Still with a commitment to innovation and customer satisfaction, the company has recently developed a structural flooring solution that brings specific benefits to the housebuilding sector.
The Working Platform is a system that is designed to enhance the construction process by providing robust support during upperfloor installations, eliminating the need for scaffold support.
But first a quick recap on Staircraft’s background. Founded in 1984, Staircraft has grown into a leading manufacturer of engineered timber products. The company operates multiple facilities across the Midlands, including factories in Coventry and West Bromwich, which collectively span over 200,000ft2. This expansion reflects its commitment to meeting the demands of the housebuilding sector while ensuring the highest standards of quality and efficiency.
The mission revolves around enhancing building efficiency through innovative solutions. The company is currently the only UK manufacturer of floor kits, I-joists and staircases.
As part of the Travis Perkins group, Staircraft benefits from a vast network of industry connections and resources.
WORKING PLATFORM
This Working Platform floor system was developed by the company to improve the way upper floors are constructed in the housebuilding sector. By integrating with standard floor installations, it eliminates the need for traditional underpropping, which can be both time-consuming and costly. The system supports heavy loads at strategic points, allowing for immediate access to upper floors once the decking is in place.
It can accommodate various loads, including block stacks and scaffolding materials, without the need for additional reinforcement. This versatility makes it suitable for a wide range of construction projects.
The timber-based system is constructed from the same materials used in conventional floors, including I-joists and metal hangers. However, it is engineered to withstand higher temporary loads typically encountered during construction. This enhanced strength means that the Working Platform is 15-30% stiffer than standard floors, which also offers a more rigid feel for homeowners once the building is completed.
By removing the need for scaffolding, the system reduces the risk of accidents on site, while workers benefit from a stable working environment, allowing for safer material handling and installation processes.
Eliminating the need for scaffolding not only cuts down on material costs but also accelerates the construction timeline. Builders can begin loading materials onto the floor immediately after installation, potentially saving two to five working days per site.
To support its customers, Staircraft offers training sessions and resources that help builders understand the best practices for using all its products. This educational approach not only enhances the customer experience but also ensures that projects are completed efficiently and safely.
WORKING PLATFORM QUESTIONS AND ANSWERS
- What is it made of and how is it made?
Working Platform is made from the same I-joists, metal joist hangers and floor decking materials used in conventional floor construction, but the floor is designed to support construction materials being stored on the floor during the building process. Because these temporary construction loads are often higher than those imposed when the dwelling is completed and inhabited, the joists sizes, spacings and metal hanger specification will sometimes need to be uprated over those which would normally be sufficient when the house is lived in. This avoids the need to use scaffolding to temporarily prop the floor during construction, saving scaffolding costs and providing clear access beneath the floor for trades to continue.
- What is its load capacity and how much stronger is it than a normal floor?
Floors constructed using the system will typically be 15-30% stronger/stiffer than conventional floors, meaning that the floor will feel more rigid to homeowners during occupancy.
- How does the overall cost compare with a normal floor?
The enhanced material specifications used in Working Platform floors will typically add between £50-£150 to the material costs of a conventional floor. This will be more than offset by the savings it yields in removing the costs of installing and removing temporary scaffolding, as well as speeding up the build programme.
• What type of loads are applied to floors during construction?
Case 1: Blockwork must be loaded out in 450mm x 450mm stacks, on timber pattresses at no less than 1.5m centres and at least 900mm from external walls. Each stack must contain max 14 No. blocks.
Case 2: Where block stack loads are applied to the floor via a scaffold system, all scaffold standards must sit on double 38 x 225mm scaffold boards spanning perpendicular to the joists.
Case 3: A single stack of plasterboard or chipboard, laid flat, may be loaded out on the floor no further than 1m from external walls, provided it is no higher than 450mm for chipboard or standard plasterboard or 350mm for all other plasterboard types.
The Working Platform exemplifies Staircraft’s dedication to enhancing construction efficiency while addressing industry challenges. As the business continues to innovate and expand, it remains focused on delivering products and services that contribute to the success of its customers and the broader construction community.
SUSTAINABILITY ENGRAINED
The business is focused on a number of sustainability improvements involving reducing waste throughout its production processes. By adopting lean manufacturing principles, Staircraft is minimising excess material usage and ensuring that any waste generated is either recycled or repurposed. For instance, offcuts from stair production are made into smaller products or materials, effectively giving them a second life and reducing landfill contributions. This approach not only conserves resources but also enhances operational efficiency. Biomass fuel is also used at its Bayton Road and Ansty factories to provide energy, reducing overall carbon footprint and energy output.
In addition to waste reduction, the business is also prioritising energy efficiency in its manufacturing facilities. Investing in machinery and optimising production workflows is significantly lowering energy consumption. This reduces the carbon footprint and results in cost savings, which can be reinvested into further sustainability initiatives and offset some of the recent material price rises.
Sourcing sustainable materials is another active policy and means selecting timber from responsibly managed forests and using eco-friendly finishes that are safe for both the environment and consumers. Ensuring that their materials meet stringent sustainability criteria contributes to the preservation of natural resources.
Staircraft has Environmental Product Declarations (EPDs) for all of its products, including stairs, landing balustrades, chipboard floors, and I-joists, to help customers understand and manage their environmental impact.
