Delivering a Consistent Solution Across Two Live Environments
The existing balcony construction presented a series of challenges typical of ageing residential assets. Timber decking and joists had degraded over time, creating safety concerns, while combustible materials no longer met modern fire safety legislation.
In addition, variations in balcony layouts, structural interfaces and levels across buildings required a solution that could be standardised without compromising adaptability. The new system needed to eliminate combustible materials, provide structural consistency, reduce slip risk, and deliver long-term durability with minimal maintenance, and all while being installed within fully occupied retirement communities.
Working closely with ExtraCare and First in Service, Dura developed a coordinated solution capable of being deployed consistently across both villages.
A Phased Aluminium Approach for Performance and Efficiency
The solution evolved across phases, beginning with Dura Deck® Aluminium Free-Drain boards to replace degraded timber with a proven, slip-resistant and free-draining surface.
As the programme progressed, the system transitioned into the latest addition to the Dura decking portfolio – d² Quickspan® Aluminium Decking. The natural next step, this best-in-class aluminium decking enhances spanning capability, reducing substructure requirements, and improving installation efficiency while maintaining consistent performance and compliance.
Central to the solution, d² Quickspan Beam replaced traditional timber joists, providing a non-combustible aluminium structure with integrated support, adjustability and consistent performance across varying balcony conditions.
Together, the decking and beam system created level, durable and maintenance-free balcony walkways, adaptable to the complexities of the existing buildings.
Minimising Disruption While Upgrading Critical Infrastructure
Delivering the remediation across two occupied retirement villages required careful coordination to ensure resident safety and minimise disruption.
The lightweight, modular nature of the aluminium system enabled efficient handling and installation within constrained access environments, reducing programme time and on-site impact compared to traditional materials.
By standardising the solution across both sites, ExtraCare achieved consistency in compliance, performance and appearance, while simplifying future maintenance and long-term asset management.
Supporting Circular Economy and Whole-Life Performance
Manufactured in the UK using aluminium with approximately 68% recycled content, the system supports reduced embodied carbon compared to traditional construction approaches.
The enhanced spanning capability of the Quickspan® system reduced the volume of substructure required, further lowering material use and associated carbon impacts.
With 100% recyclability at end of life and significantly lower maintenance requirements than timber, the solution aligns with circular economy principles while reducing whole-life cost and environmental impact.
Results and Impact
- Full removal of life-expired and combustible timber balcony systems
- Installation of a non-combustible aluminium decking and substructure solution
- Compliance with modern fire safety requirements across both villages
- Standardised solution delivered across multiple buildings and configurations
- Reduced material use through enhanced spanning capability of Quickspan®
- Improved durability with minimal maintenance requirements over the asset life
- Enhanced resident safety with ultra-low slip potential surfaces
- Efficient, phased installation within live residential environments
- A consistent, modern aesthetic supporting high-quality living standards
- Circular, UK-manufactured solution with 68% recycled content and full recyclability
