GB2437180A

GB2437180A - Acoustic Flanking Block

Info

Publication number: GB2437180A
Application number: GB0707163A
Authority: GB
Inventors: Iain Mcgregor Fairnington
Original assignee: A Proctor Group Ltd
Current assignee: A Proctor Group Ltd
Priority date: 2006-04-13
Filing date: 2007-04-13
Publication date: 2007-10-17
Also published as: GB0607408D0; GB0707163D0

Abstract

A flanking block 1 for use in the acoustic insulation of floating floor systems comprises an elongate length of resiliently deformable insulating material. The flanking block has an upper face (2 figure 1a), a wall-abutting face 4 generally perpendicular to the upper face and a base face (6 figure 1a) generally parallel to the upper face and generally perpendicular to the wall-abutting face. The base face is wider than the upper face and a screed facing face 8 extends between the base face and the upper face. The flanking block preferably has a series of parallel horizontal pre-cuts 12 which run through the block which allow easy removal of excess material. The flanking block also preferably has an adhesive layer (14 figure 1b) and 22 of double sided adhesive tape on the base face and or screed facing face to secure it in position and also prevent the screed from leaking underneath the flanking block. An acoustic insulation system and a floating floor construction, utilising the flanking block, are also provided, together with a method of construction for the floating floor.

Description

ACOUSTIC FLA1KING BLOCK The present invention relates to a flanking

block for use in a sound (acoustic) insulation system for screed finish floors.

With increasing demand for quiet homes and dwellings and the general intolerance of noise transfer between dwellings in multiple occupancy housing, the government, through the relevant authorities, has continually increased the requirements in the building regulations for improved acoustic separation between walls and floors. In particular the current Part E building regulations.

Furthermore any systems and installations to address and resist the passage of sound require to meet the Robust Details' construction solutions. Robust details' are construction solutions which provide an alternative to pre-completion sound testing as a method of complying with Part E of the building regulations and essentially allows builders to build to certain specifications and drawings and these systems are deemed robust enough to allow for variances in the quality of workmanship yet still meet the numerical requirements of the relevant regulations.

Conventionally it is known to provide a floating screed on top of a floor construction and to isolate the screed from the floor utilising a layer of resilient sheeting. It is a requirement of the building regulations that the floating screed be isolated and not bridge the adjacent wall and thus it has been known to either extend the layer of resilient material up the side of the wall or to use a flanking strip for sound insulation. Such flanking strips generally comprise a strip of 10mm foam placed vertically on the wall which abuts with the resilient base layer.

Alternatively there can be used a 15mm expanded or extruded polystyrene, or indeed a 25mm mineral fibre batt. Whilst such systems have been promoted and approved by the Robust Details program, it has recently become apparent that there are problems with the impact performance of floating screed flooring upon a concrete floor structure to the extent that the separating floor does not meet the acoustic performance required by the building regulations. Inspections of these sites have shown three potential causes of flanking transmissiOn in the construction which significantly affects the performance of the installation. Specifically the problems that are encountered are that the isolating/insulating flanking strip is not installed or is not installed properly resulting in the floating concrete screed bridging with the wall; the flanking/isolating edge strips that have been installed have been cut off by subsequent tradesman therefore negating the isolation; or the isolating/insulation strips not being installed in sufficient length or adequately in corners to ensure the installation meets the required separation and specification. Furthermore existing flanking strips can be difficult to inspect after installation which can result in the installation not meeting the relevant regulations.

Other problems that have been identified is the tendency for flanking strips or existing flanking arrangements to move and float as the concrete screed is laid on the flooring installation.

Furthermore known flanking strips generally comprise relatively expensive to manufacture shapes and/or materials and the reduction in material costs is a prime consideration for builders. Furthermore ease of use is of particular significance to builders.

It is an object of the present invention to avoid or minimise one or more of foregoing disadvantages.

The present invention provides a flanking block for use in the acoustic insulation of floating floor systems, said flanking block comprising an elongate length of resiliently deformable insulating material having an upper face, a wall-abutting face generally perpendicular to said upper face, a base face generally parallel to said upper face and generally perpendicular to said wall-abutting face, said base face being wider than said upper face, and said base face and said upper face having a screed facing face extending therebetween.

Thus with a flanking block according to the present invention it is possible to provide acoustic insulation of a floating floor system such that the floating floor system meets the relevant building regulations and Robust Details construction requirements.

It will be understood that the flanking block of the invention may be used with any floating floor material, such as, for example, timber or other board materials, as well as with a screed floating floor. In each case the screed facing face faces outwards from a wall in use towards the floating floor material.

preferably the screed facing face is planar i.e. the screed facing face is an inclined plane facing outwards from a wall against which, in use, the flanking block is placed.

Alternatively the screed facing face may be contoured e.g. convex or concave. For example, the screed facing face may comprise a vertical portion as well as an inclined portion as described hereafter with reference to specific embodiments.

The flanking block of the invention presents a number of advantages when compared to previous devices such as the aforementioned flanking strips. By having a base face that is wide relative to the top face the flanking block, when placed in position, is stable and less likely to fall over or be displaced during the floor installation process. The screed facing face of a flanking block, placed in position for use, projects downwards and outwards as it extends between the upper face and the base face. Therefore when the flanking block is installed with a floating floor, the floating floor material, for example a screed material, extends over at least a portion of the screed facing face.

This has the beneficial effect of assisting in securing the flanking block in its correct position. The weight of the floating floor material overlying the screed facing face acts to hold the flanking block down, as well as locating the flooring material against the wall. This is particularly advantageous when a screed material is used for the floating floor. When the screed material is poured or spread on top of the resilient sheeting to form the floor, there can be a tendency for prior art flanking strips to float out of position very easily, resulting in the screed bridging to the wall thus losing sound insulation.

Advantageously the flanking block of the invention further comprises at least one edge extension portion. The edge extension portion may be a vertical edge extension portion comprising a sheet material extending vertically upwards as a continuation of the wall abutting face. Alternatively the edge extension portion may be a horizontal edge extension portion comprising a sheet material extending horizontally as a continuation of the base face of the flanking block from the junction between the base face and the screed facing face. A flanking block may be fitted with both vertical and horizontal edge extension portions.

Generally the edge extension portions run continuously along the whole length of the flanking block, but may be discontinuous if desired. The edge extension portions are relatively thin layers of a suitable sheet material, which is bonded to the flanking block. Suitable sheet materials include but are not restricted to cross-linked polyethylene, closed cell polyethylene foam or an open cell polyurethane foam. The edge extension portions are preferably 5mm or less in thickness. Typically the edge extensions extend up to 100mm from the edge of the flanking block, but any desired width may be employed. The edge extension portions are easily trimmed to size if required.

Edge extension portions are generally attached to their flanking block in the factory. The extension portion or portions may be bonded to the flanking block by thermal bonding, adhesive bonding, or by taping.

A vertical edge extension portion serves as a means for rapid and easy attachment of the flanking block to a wall.

The flanking block is positioned in place against a wall and staples or other suitable fixings can be driven through the extension portion at suitable intervals along the length of the flanking block. After the floor installation is completed the staples may be removed and the edge extension portion trimmed or cut off if desired.

A horizontal edge extension portion can also be used to rapidly fix the flanking block to the floor with fixings such as staples, in the same manner as described above for fixing a vertical edge extension portion a wall. However it can also serve other purposes. The relatively thin edge extension portion overlies and thus links to the layer of resilient sheeting ("acoustic membrane") which isolates the screed or other floating floor material from the base floor, helping to provide secure sound insulation. It also serves, where a screed floating floor is laid, to act to prevent the screed leaking underneath the flanking block before it sets.

Flanking blocks with edge extension portions have been found to provide a better fit at the wall and floor junction, especially where walls and base floors are irregular. This reduces even further the possibility of bridging beLweerl the floating floor material and the adjacent wall.

Preferably each end of a flanking block of the invention is formed for abutting to an end of another flanking block.

This avoids the need for cutting the ends of lengths of flanking block when placing them side-by-side along a wall in use. For example the ends of the flanking blocks may simply be plane faces, perpendicular to the upper, base and wall-abutting faces.

preferably the flanking block of the invention further comprises bonding means for fixing the flanking block into position. For example the flanking block may have an adhesive portion on its wall-abutting and/or on its base face. The adhesive portion may be provided by means of a double-sided adhesive tape located on either or both of the wall abutting or the base face. In use these adhesive surfaces are used to fix the flanking block of the invention to a wall, the sub floor or the resilient sheeting placed on a sub floor. Alternatively the flanking blocks may be attached, in use, by other bonding means to the floor or wall. For example lengths of adhesive tape may be applied across the screed facing face and the resilient sheeting layer during construction of the floating floor. This has the advantage that the tape acts to prevent any leakage of screed material under the flanking block.

Advantageously the flanking block of the invention may be formed and arranged to be frangible at a pre-determifled place or places near the top of the block. For example, the block may have a series of parallel horizontal pre-cuts running partially through the width of the block. In use, after a floor has been laid in conjunction with the flanking blocks of the invention, excess block material, projecting above the level of the floating floor material, may be easily removed by breaking or cutting through at a selected height along the plane of one of the pre-cuts.

preferably the screed facing face is provided with a series of markers so that when the screed is being laid the depth of the flanking block can be readily seen.

preferably the resilientlY deformable insulating material comprises a closed cell polyethylene foam with a density in the range of from lOkg/m3to 60kg/rn3, desirably 30kg/rn3.

Alternatively there may be used expanded or extruded polystyrene, provided such material can be manufactured so as to comply with the Robust Details requirements.

Alternative materials could include cork, rubber or mineral fibre.

Foam is particularly desirable as it is robust, easily installed, easily cut and handled on site and requires no specialised tools or cutting equipment or handling.

Typically the flanking blocks are supplied in lengths of 2.4m, but any desired length can be used. A typical flanking block for use with screed floating floors will be of the order of 65mm high with an upper face of about 10mm width and a base face of about 60mm width. Other dimensions can be used to suit the depth and type of floating floor being laid.

When laying flanking blocks, as part of the acoustic insulation for a floating floor system, the flanking blocks run round the entire perimeter of all walls which are required to be insulated from the floating floor. At corners the flanking blocks may simply be cut to provide rnitred joints running round the corners. Alternatively specially shaped corner portions, which are part of a flooring system, which constitutes another aspect of the present invention, may be provided.

Thus according to another aspect the present invention provides an acoustic insulation system for floating floors, said system comprising flanking blocks, wherein said flanking blocks are formed to abut end to end against each other in use and comprise elongate lengths of resiliently deformable insulating material each having an upper face, a wall-abutting face generally perpendicular to said upper face, a base face generally parallel to said upper face and generally perpendicular to said wall-abutting face, said base face being wider than said upper face, and said base face and said upper face having a screed facing face extending therebetween.

Preferably the acoustic insulation system further comprises corner flanking blocks, said corner flanking blocks being formed and arranged for placement at a corner between two walls in use of the acoustic insulation system, to provide continuity of acoustic insulation between flanking blocks placed along each of the said two walls. The corner blocks are preferably formed to have similar height and width to the flanking blocks. They have end faces that abut, without spaces in-between, the end faces of the flanking blocks, to prevent any bridging to a wall caused by a flooring material such as a screed passing through a gap.

Preferably the corner flanking blocks have screed facing faces that project downwards and outwards from the upper face of the corner flanking block. The corner flanking blocks may be fitted with edge extension portions similar to those that may be fitted to the flanking blocks.

According to a third aspect the present invention provides a floating floor construction comprising: a layer of resilient sheeting supported on a sub-floor; a layer of floating floor material supported on said layer of resilient sheeting; and flanking blocks, along at least one edge of said layer of floating floor material and separating it from a wall, wherein said flanking blocks comprise elongate lengths of resiliently deformable insulating material each having an upper face, a wall-abutting face generally perpendicular to said upper face, a base face generally parallel to said upper face and generally perpendicular to said wall-abutting face, said base face being wider than said upper face, and said base face and said upper face having a screed facing face extending therebetween.

Preferably said floating floor material is a screed material. The sub floor may be of any type, typically of concrete, wood or steel construction.

According to a fourth aspect the present invention provides a method for constructing a floating floor comprising the steps of: providing a layer of resilient sheeting and positioning it on a sub-floor; providing flanking blocks according to the invention and placing them along at least one wall adjacent said sub-floor; and providing a floating floor material and placing it on top of the layer of resilient sheeting and abutting the flanking blocks.

Further preferred features and advantages of the present invention will now be described with reference to the accompanying drawings in which: -Figs. l(a,b) shows in a perspective and elevation views view an embodiment of a flanking block of the invention; Figs. 2(a,b) shows schematically, in elevation, floor constructionS of the invention; Figs. 3(a,b) show in perspective views, flanking blocks as in figure 1 together with corner flanking blocks forming an acoustic insulation system of the invention; Figs. 4(a,b) shows, in elevation, an alternative embodiment of the flanking block of the invention and its use in a floor construction; and Fig. 5 shows a further embodiment of a flanking block of the invention and its use in a floor construction.

Figure la shows a flanking block 1 of the invention. The block 1 is an elongate length of closed cell polyethylene foam. It has an upper face 2, a wall-abutting face 4, and a base face 6, which has an adhesive layer (see figure ib) A screed facing face 8, which in this example is planar, extends from the upper face 2 to the base face 6. Each end of the flanking block 1 has a planar end face 10, which is perpendicular to the upper face 2, the wall-abutting face 4 and the base face 6. The flanking block 1 has a series of parallel horizontal pre-cuts 12, which run partially through the block 1.

Figure lb shows the flanking block 1 of figure la in elevation. An (optional) adhesive layer 14 of a double sided adhesive tape is located on the base face 6 of the flanking block 1.

The use of the flanking block of Figure 1 is shown in Figures 2a and 2b. Figure 2a shows in a schematic elevation a floor constructiOn using the flanking block 1 of figure 1. A concrete sub floor 16, bounded by a wall 18, has a layer of resilient sheeting 20 laid upon it. The flanking block 1 is positioned on the resilient sheeting 20 with its wall-abutting face 4 against the wall 18. A layer of adhesive tape 22 is used to fix the flanking block 1 in position and also serves to prevent screed material leaking under the flanking block 1. A screed floating floor 24 is then laid on top of the resilient sheeting 20 and also lies on a portion of the screed facing face 8 of the flanking block 1. The flanking block prevents the screed material reaching the wall 18 and acts an acoustic insulator. If desired the top of the flanking block 1 may be trimmed, for example at the point labelled X, by cutting through to the appropriate pre-cut 12.

Figure 2b shows a similar floor construction to that of Figure la except that the resilient sheeting layer 20 does not pass under the flanking block 1. Instead an edge portion 26 of the resilient sheeting 20 is positioned to overlap the screed facing face 8 of the flanking block 1, thus acting to prevent screed material passing under the base face 6 of the flanking block 1.

Figure 3a shows a corner flanking block 28 in use with flanking blocks 1 in the acoustic insulation system of the invention. The corner flanking block 28 has wall-abutting faces 29, at right angles to each other, to fit into a corner where two walls meet (not shown) . The corner flanking block 28 has vertical end faces 30 which match and abut against the end faces 10 of the flanking blocks 1. A sloping screed facing face 32 is provided on the front of the corner flanking block 28.

Figure 3b shows a similar arrangement to that of Figure 3a except that the corner flanking block 28 is formed for use where the acoustic insulation is to pass round an outward projecting corner.

Figure 4a shows an alternative form of flanking block 1 to that of Figure 1. The flanking block 1 has a contoured screed facing face 8, which includes an extended vertical portion 34. The vertical portion 34, which is easily trimmed as required, can be useful when laying a screed floating floor on a sub floor which is not level. This is illustrated schematically in Figure 4b. In figure 4b the sub floor 16 is not level and so the screed floating floor 24, which has been properly levelled, is thicker at one end 36 than the other. This leads to screed material 38 reaching higher up the screed facing face 8 of the flanking block than intended requiring the extended vertical portion 34 to prevent bridging of the floating floor 24 to the wall 18.

Figure 5 illustrates a further embodiment of a flanking block 1, fitted with edge extension portions. The flanking block 1 is fitted with a vertical edge extension portion 40 of 5mm thick open cell polyurethane foam extending from the top of the wall abutting face 4. The edge extension portion 40 is fixed by staples 42 (only one shown) to the wall 18, thus securing the flanking block 1 in place while a screed floating floor 24 is laid. A horizontal edge extension portion 44 of the same material as the vertical edge extension portion 42 extends from the base face 6 of the flanking block 1. The horizontal edge extension portion 44 overlies the resilient sheeting layer 20 and acts to link the flanking block 1 to it. It also assists in preventing the screed layer 24 from leaking under the flanking block 1 before it is set.

Claims

CLAIMS

1. A flanking block for use in the acoustic insulation of floating floor systems, said flanking block comprising an elongate length of resiliently deformable insulating material having an upper face, a wall-abutting face generally perpendicular to said upper face, a base face generally parallel to said upper face and generally perpendicular to said wall-abutting face, said base face being wider than said upper face, and said base face and said upper face having a screed facing face extending the rebetween.

2. A flanking block according to claim 1 wherein the screed facing face is planar.

3. A flanking block according to claim 1 wherein the screed facing face comprises a vertical portion and an inclined portion.

4. A flanking block according to any one of claims 1 to 3, wherein the flanking block further comprises at least one edge extension portion.

5. A flanking block according to claim 4 wherein the edge extension portion is a vertical edge extension portion of a sheet material extending vertically upwards as a continuation of the wall abutting face.

6. A flanking block according to claim 4 wherein the edge extension portion is a horizontal edge extension portion of a sheet material extending horizontally as a continuation of the base face of the flanking block, from the junction between the base face and the screed facing face.

7. A flanking block according to any one of claims 4 to 6 wherein the edge extension portion is 5mm or less in thickness.

8. A flanking block according to any one of claims 4 to 7 wherein the edge extension portion is of a cross-linked polyethylene, a closed cell polyethylene foam, or an open cell polyurethane foam sheet material.

9. A flanking block according to any preceding claim wherein each end of the flanking block is formed for abutting to an end of another flanking block.

10. A flanking block according to any preceding claim further comprising bonding means for fixing the flanking block into position.

11. A flanking block according to claim 10 wherein the bonding means is an adhesive portion on the wall abutting face and/or the base face of the flanking block.

12. A flanking block according to any preceding claim formed and arranged to be frangible at a pre-deteriflifled place or places near the top of the block.

13. A flanking block according to claim 12 wherein the flanking block has a series of parallel horizontal pre-cutS running partially through the width of the block 14. A flanking block according to any preceding claim wherein a series of markers are provided on the screed facing face.

15. A flanking block according to any preceding claim wherein the said resiliently deformable insulating material comprises a closed cell polyethylene foam of a density within the range of from lOkg/m3to 60kg/rn3.

16. A flanking block according to claim 15 wherein the closed cell polyethylene foam has a density of 30kg/rn3.

17. A flanking block according to any one of claims 1 to 14 wherein the said resiliently deformable insulating material comprises expanded polystyrene, extruded polystyrene1 cork, rubber, or mineral fibre.

18. An acoustic insulation system for floating floors, said system comprising flanking blocks, wherein said flanking blocks are formed to abut end to end against each other in use and comprise elongate lengths of resiliently deformable insulating material each having an upper face, a wall-abutting face generally perpendicular to said upper face, a base face generally parallel to said upper face and generally perpendicular to said wall-abutting face, said base face being wider than said upper face, and said base face and said upper face having a screed facing face extending therebetween.

19. An acoustic insulation system according to claim 18 further comprising corner flanking blocks, said corner flanking blocks being formed and arranged for placement at a corner between two walls in use of the acoustic insulation system, to provide continuity of acoustic insulation between flanking blocks placed along each of the said two walls.

20. An acoustic insulation system according to claim 19 wherein the corner flanking blocks have a similar height and width to the flanking blocks and have end faces that abut, without spaces in-between, the end faces of the adjacent flanking blocks.

21. An acoustic insulation system according to claim 19 or claim 20 wherein the corner flanking blocks have screed facing faces that project downwards and outwards from the upper face of the corner flanking block.

22. A floating floor construction comprising: a layer of resilient sheeting supported on a sub-floor; a layer of floating floor material supported on said layer of resilient sheeting; and flanking blocks, along at least one edge of said layer of floating floor material and separating it from a wall, wherein said flanking blocks comprise elongate lengths of resiliently deformable insulating material each having an upper face, a wall-abutting face generally perpendicular to said upper face, a base face generally parallel to said upper face and generally perpendicular to said wall-abutting face, said base face being wider than said upper face, and said base face and said upper face having a screed facing face extending therebetween.

23. A floating floor construction according to claim 22 wherein the floating floor material is a screed material.

24. A floating floor construction according to claim 22 or claim 23 wherein the sub floor is of concrete, wood or steel.

25. A method for constructing a floating floor comprising the steps of: providing a layer of resilient sheeting and positioning it on a sub-floor; providing flanking blocks according to the invention and placing them along at least one wall adjacent said sub-floor; and providing a floating floor material and placing it on top of the layer of resilient sheeting and abutting the flanking blocks.

26. A flanking block substantially as hereinbefOre * described and with reference to figures 1,2 and 3 of the drawings.

27. A flanking block substantially as hereinbefore described and with reference to figure 4 of the drawings.

28. A flanking block substantially as hereinbefore described and with reference to figure 5 of the drawings.