Millenium Village Project

Scope of Work: The Millennium Village Project, a prestigious apartment development located in London’s Docklands, is known for its luxurious design and prime waterfront location. The project, designed to offer premium living spaces, encountered a structural challenge during construction that threatened to disrupt both timelines and the high standards expected for such an exclusive development. Midway through construction, a critical issue arose when it was discovered that the floor slab in several areas had insufficient reinforcement in its top section.

The discovery of insufficient reinforcement in the top section of the concrete floor slab posed a serious concern for the structural integrity of the building. To complicate matters, the concrete deck was already the finished floor level, and essential components such as partitions, mechanical and electrical (M&E) systems, and door sets had been installed. This made it impractical to increase the thickness of the slab or remove and replace it without causing major delays, additional costs, and significant disruption to the ongoing construction process.

The challenge was to find a solution that would strengthen the slab without affecting the aesthetics of the finished floors or halting the progress of the project. A quick, efficient method was needed to maintain the project’s momentum while ensuring the necessary structural integrity.

CCUK’s design team developed an innovative carbon fibre reinforcement system to address the lack of reinforcement. After a thorough assessment, they selected Carbon Fibre Reinforced Polymer (CFRP) from one of CCUK’s preferred suppliers as the ideal material for this task. Carbon fibre was chosen for its exceptional strength, lightweight properties, and ease of installation.

The carbon fibre system was designed with a maximum thickness of just 3mm, which allowed it to be recessed into the existing slab by planing down the concrete surface without compromising the structural integrity. This approach provided the necessary reinforcement around the weakened sections without affecting the floor’s finished appearance or causing major disruption to the project.

The solution was applied to over 150 square metres of the slab surface. CCUK’s expert installation team prepared the surface and applied two layers of the carbon fibre system, known as Fibre wrap, ensuring that the stresses caused by the cutting of reinforcement were effectively transferred and managed.

The project was successfully completed within just three weeks, causing minimal disruption to the ongoing construction of the Millennium Village Project. By implementing the carbon fibre strengthening solution, the structural integrity of the floor slab was fully restored, allowing construction to continue on schedule and within budget.

The innovative use of carbon fibre meant that the solution was applied quickly and discreetly, without affecting the appearance of the floors or other structural elements. This high-strength, low-profile reinforcement ensured that the luxurious aesthetic of the apartment interiors was maintained, preserving the high standards expected for this exclusive development.

The success of the carbon fibre strengthening not only resolved the structural issue but also demonstrated the versatility and effectiveness of advanced materials like CFRP in challenging construction environments. CCUK’s ability to deliver a bespoke, efficient solution ensured that the Millennium Village Project remained on track, delivering premium living spaces in one of London’s most sought-after locations.