The innovative use of thermal breaks in concrete flooring

Two apartment blocks in a Brooklyn, New York neighbourhood feature innovative use of structured thermal breaks in the concrete flooring of the five elevated walkways that connect the buildings.

The concrete flooring has thermal breaks made from insulation which is penetrated by stainless steel to provide structural strength. The steel is tied into the slabs before the concrete is poured. This thermal break technology reduces heat loss by up to 88% whilst preventing condensation from forming that could cause mould.

The challenge the construction team faced on the walkaways was that they curve and pitch with the floor thickness, varying between 9 and 11 inches. First, the thermal breaks were installed, followed by a system that melts snow. The concrete was then poured, before adding retardant that enabled time for a low-pressure power wash that created an aged look. The walkways have no walls, so a mesh enclosure was erected for safety. Pedestrians on the walkways feel as if they are high up outside, yet are safe.

Jason Tipold, the project structural engineer, said that the walkways bring the two buildings together:

“The thermal breaks are a huge part of that, as they connect the walkways to the apartment units on all five levels.”

Concrete slabs were used to build the walls of the apartments, and these also had thermal breaks to prevent heat transfer. Thermal windows reflect heat back in the room on chilly days.

The high insulation standard of the building is designed to cope with extreme New York weather conditions.