May Danskin. Thermal Saddle System. Level, insulate and reduce air leakage and all with one flooring system. Danskin

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1 May 2007 Thermal Saddle System Level, insulate and reduce air leakage and all with one flooring system

2 Thermal Saddle System Introduction The requirements for the thermal insulation of buildings in England and Wales were revised with effect from April For new dwellings these are set out in Approved Document L1A. In Scotland the requirements are detailed in Section 6 of the Technical Handbook which came into force in May These revisions have focussed attention on the methods of insulating ground floors, concentrating particularly on energy efficiency, performance and the need for easy integration with the structure. The Thermal Saddle System have adapted their successful Acoustic Saddle Flooring System to provide an easy way to install a level, thermally insulated floating floor on uneven subfloors without the need for levelling screeds. The system is suitable for installation above suspended beam & block and precast plank floors or on upper floors with an exposed soffit. It is also suitable for use on a cast in situ concrete ground floor provided a suitable DPM and vapour control layer are installed. BENEFITS : Eliminate the levelling screed Suspended beam and block and precast plank floors are generally uneven and would normally require the application of a levelling screed before laying insulation. `s patented packing system means that uneven floors can be levelled quickly and easily without delay, reducing the incidence of creaking floors. Superior Performance The Thermal Saddle System can provide U Values as low as 0.19 W/m 2 K depending on the subfloor construction, the insulation and the perimeter/area ratio. This design flexibility is invaluable when trying to achieve Target Emission Rates. Continuity of insulation For energy efficient performance it is essential that gaps in the insulation are avoided, particularly at the perimeter of the floor. A perimeter insulating trim is supplied which insulates the perimeter while a foam upstand on the trim ensures that an expansion gap is maintained for the chipboard. This design permits the use of Accredited Details at the perimeter of the floor. have developed an innovative new saddle style so that insulation boards do not have to be shaped. The saddles and packers carry the insulation boards for quick installation and the insulation is supplied precut to suit standard batten centres. Minimal Floor Height As the insulation is carried within the floor the Thermal Saddle System can save over 30mm in height when compared to a 65mm screed laid upon an equivalent thickness of insulation. Significant weight savings are also achieved. Environmentally Friendly The resilient layer on Saddles is recycled and has no Ozone Depletion Potential or Global Warming Potential. When installed on a beam and block ground floor and incorporating a plywood deck the floor achieves an A rating according to the BRE Green Guide to Housing Specification (2000 Edition). Underfloor Heating Integration Companies such as OSMA and Nu-Heat manufacture rigid insulation panels incorporating underfloor heating systems which can be easily integrated with the Thermal Saddle System in place of standard insulation panels. See back page for more information. Robust Details Compliance The system can be used as an FFT2 product on separating floors or as a floating floor on ground floor raft foundations with an appropriate wall detail.

3 System Performance Thermal Saddle System U-value tables using Knauf Polyfoam (U-values in W/m 2 K for given P/A Ratios ) Data courtesy of Knauf Insulation calculated using BS EN ISO 13370:1998. Please refer to Approved Document L1A (England and Wales) or the Technical Handbook (Scotland) for guidance on acceptable U values. Figures in red indicate non compliance with a maximum 0.25 U Value. 85mm boards are a non stock item and may be subject to a lead in time. The system is available with alternative insulation materials where particular performance or environmental properties are required. Please contact for advice. E&OE. Information believed to be accurate at time of printing. Specifications may change without prior notice. Beam and Block ( with dense infill blocks ) 22mm Chipboard on bearers at 600mm centres 50mm mm mm Precast Concrete Plank ( Minimum 150mm thick ) 22mm Chipboard on bearers at 600mm centres 50mm mm mm Beam and Block ( aircrete block with lambda 0.16 W/mK ) 22mm chipboard on bearers at 600mm centres 50mm mm mm Cast In-situ Slab 22mm chipboard on bearers at 600mm centres 50mm mm mm Typical Perimeter Detail Perimeter Insulating Strip 2. Precut Insulation Boards 3. Egger Protect Chipboard 4. Mastic Bead 5. Colour Coded Packer 6. Elevating Blocks 5 6

4 System Components Systems are designed and constructed using the following components: Flooring prefer the use of 22mm thick Egger Protect P5 Moisture Resistant Grade Chipboard (CE marked chipboard manufactured to BS EN 312 : Part 5). The chipboard is faced on both sides with thermosetting resin impregnated paper which, according to Egger, negates the need for a Vapour Control Layer immediately below the board providing a suitable DPM is in place. All panels are tongued and grooved on all four edges and supplied in sheet size 2400 x 600mm. Where ordinary unfaced P5 chipboard flooring or plywood is used a vapour control layer of minimum 500 guage polythene (by others) should be laid above the insulation and below the floor boarding to protect it from residual moisture in the concrete absorbed during construction or from exposure of the slab to the weather. Where necessary, WBP Spruce Plywood, CE marked and manufactured to BS5268-2:2002 can be supplied. Support Bearers (Preservative Treated Timber) Preservative treated Softwood Support Bearers are placed within the saddles to support flooring panels. They are 47mm (Nom.) wide and supplied in 1800mm lengths for ease of handling. They are available 52mm high, 77mm high and 87mm high for use with 50mm, 75mm and 85mm insulation foam. The bearers are strength graded to comply with TRADA recommendations on spanning elements. The bearers are laid at 600 mm centres when used under normal domestic loadings (UDL of 1.5kN/m 2 and concentrated load of 1.4kN). All timber is ordered from legal and sustainable sources and is generally PEFC certified. Perimeter Insulating Strip Perimeter Insulating Strips are placed at the edge of the floor to insulate the gap between the wall and the perimeter support bearers. They are formed from rigid insulation foam and have a flexible closed cell foam upstand bonded to one edge. The compressible closed cell foam upstand sets out the necessary 10mm perimeter expansion gap for the chipboard. Perimeter Insulating Strips are available to suit 50mm, 75mm and 85mm insulation and come in 1800mm lengths. In accordance with Accredited Details it is also recommended that a non setting mastic bead is applied between the skirting board and the top of the flooring to prevent air leakage. Precut Insulation Boards The Thermal Saddle System incorporates Knauf Polyfoam extruded polystyrene insulation boards. Polyfoam has excellent thermal conductivity and low moisture absorption properties making it ideal for ground floors. The boards are prefabricated to a 2400mm x 555mm size which ensures that they fit neatly between support bearers laid at 600mm intervals without further fabrication on site. Only turn out sizes need to be cut. The boards are available in either 50mm, 75mm or 85mm thicknesses depending on U Value requirements and are carried on the protruding ends of the saddles and packers. Colour Coded Packers Packing is provided by means of innovative, self locating plastic packers which are made in 3,4,5 and 10mm thicknesses. The unique, patented packers interlock with each other and with the Saddle. They are colour coded for ease of identification and are placed within the Saddle to achieve the levelling of uneven subfloors. Thermal Saddles Thermal Saddles are 97mm x 97mm square and have a tough, injection moulded plastic headcap adhered to a high performance foam resilient layer. The recycled foam layer has excellent thermal insulating properties and is highly resistant to moisture absorption. The headcap holds the Support Bearers to which flooring panels are fixed. Each saddle headcap has two small holes in the surface to lock packing pieces in place and can accommodate 29mm of packing to level the floor. The ingenious design of the headcap means that the protruding ends of the saddles or packers fully support the precut insulation panels without having to shape the insulation in any way. The standard height of the Saddle with the resilient layer attached is 11mm. Saddles are laid at 600mm centres under normal domestic loadings. Elevating Blocks (Optional) Elevating blocks are made from injection moulded plastic and they can be placed in combination below Saddles where floor variations are extreme up to a maximum height of 150mm. They interlock with the saddles and with each other and extend the height of systems to cope with major deviations in levels. The blocks come in 15 and 30mm thicknesses.

5 Design Recommendations Dryness of Concrete Excessive moisture from cast in situ slabs and screeds which have not dried out can have adverse effects on flooring materials and timber components. BS 8201:1987 (Code of Practice for flooring of timber, timber products and wood based panel products) states that it is reasonable to recommend that the concrete be considered dry when the relative humidity falls to 75% or less (when tested by use of a hygrometer). Where the dryness of concrete cannot be guaranteed it is recommended that a vapour barrier is installed. Partitions It is anticipated that partitions will be erected from the subfloor and not on top of the floating floor. Loadings Component spacings are calculated with reference to BS6399 1:1996. In order to mitigate impact sound the floor will exhibit deflection as loadings increase. In kitchens and bathrooms Saddle centres should be reduced to 300mm. must be consulted for guidance if the design loadings exceed domestic loadings as specified in the above document or if extraordinary local loadings are anticipated. For example storage heaters, pool tables and certain granite worktops may require support direct from the subfloor, independent of the floating floor. Ceramic Tiles There are inherent risks in laying ceramic tiles on top of floating floors. However the risks can be significantly reduced by good detailing and the use of modern flexible adhesives. Ceramic tiles have been successfully laid on the Saddle System in numerous projects over many years. Contact the Sales Department for specialist advice. Underfloor Heating Saddle Systems can physically integrate with many underfloor heating systems. Please contact at an early stage if it is intended to use underfloor heating in conjunction with the Saddle System as it is important to avoid drying out of timber components. Communal Areas in Flats BS6399 1:1996 imposes more onerous load bearing requirements for communal areas in certain designs of flatted developments. Concentrated load requirements over the long term can be as high as 4.5 kn. The maximum capacity of 22mm chipboard at reduced centres is 2.7 kn. If it is intended to lay the Saddle System in communal areas in flats such as common corridors, hallways stairs and landings it is essential to contact for specific advice regarding the floor boarding and component centres. Typical Details Support of Perimeter Bearers 2 Threshold Detail 3 Support of Short Edges

6 Underfloor Heating The Thermal Saddle System with Underfloor Heating Combining the proven superior acoustic performance of the Saddle System with water based underfloor heating systems, the Thermal Saddle System can provide support for rigid insulation emitter panels ensuring direct contact with the underside of the flooring deck, enhancing the efficiency of the heating system. Benefits Easy levelling with underfloor heating integration Proven acoustic performance means system is equally suitable on ground or separating floors Independently tested to demonstrate Robust Detail FFT2 acoustic compliance Lightweight alternative to screed based systems Insulation panels can be precut to batten centres. Separating Floors The Building Regulations require that separating floors achieve stringent sound insulation performance standards. Thermal Saddle systems are proven to contribute toward meeting the acoustic performance criteria in conjunction with a suitable structural floor and ceiling Copy & Illustrtation to be supplied treatment. By utilising the floating floor void to install the underfloor heating system wall space is maximised within each dwelling. No need to plan around radiators! The Thermal Saddle System has been used successfully with both OSMA and Nu Heat underfloor heating products. It is essential to check that underfloor heating products are compatible with the system and the desired floor finish. Please contact for further information. Thermal Saddle System with OSMA underfloor heating. General Information NBS Specification clauses NBS specification clauses can be provided for any of the Saddle Systems. Installation To ensure correct installation of the floor the detailed fixing instructions must be followed carefully. Copies of these instructions should be obtained from the manufacturer. The installation of the system is simple and can be undertaken by competent carpenters. Alternatively, experienced fixing contractors can be recommended who can undertake to supply and fix the system in most areas of the United Kingdom. Storage All components should be stored inside, under cover and in dry conditions. Delivery The system is generally supplied on curtainside vehicles ready for forklift unloading by site. Patents Saddle Systems and Thermal Saddle Systems are protected by patents and patents pending. ISO 9001:2000 J & Co. Ltd. operate a quality system which has been independently assessed to ISO 9001:2000. Every care has been taken to ensure that all descriptions and specifications are believed to be correct at date of publication. The policy of J & Co. Ltd. is one of continuous improvement and product development, and the right is reserved to alter the product specifications and detailed fixing instructions without notice. `s employees or agents are not authorised to make any representations or give any advice or recommendations concerning any goods or services unless confirmed in writing. pasm J. & Co. Ltd, 1 Netherton Road, Wishaw ML2 0EQ. Telephone: Fax: enquiries@danskin.co.uk Web: