OS Thermal System Installation Guide

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1 OS Thermal System Installation Guide cube6.co.uk

2 2 A thermal resistance many times greater than aerated concrete blocks

3 It s more than just insulation CUBE6 Oversheet Thermal Floor System (OS) is the innovative, simple, fast and costeffective way to create insulated suspended ground floors. CUBE6 OS system replaces the conventional concrete infill block with a BDA tested polystyrene block. The EPS block locates between the beams and sits on the shoulder. A structural tested Oversheet is installed above the units for maximum thermal performance. The structural topping is then placed ready for following trades. Provides a costs effective, inherently simple pre-cast flooring system. Superior Performance Thermal Performance Outstanding thermal performance with U Values as low as 0.08 W/m2K and Psi values higher than accredited default values. Costs CUBE6 will design the most economic solution for the project whilst achieving the highest levels of thermal values Flexibility Complete range of polystyrene depths and grades to achieve U Value requirements and site specification Lifetime Performance EPS units will maintain their performance for the lifetime of the building and beyond BDA Approval & CE Marking BDA Agrément BAF /01/A. CE Marked to BS EN :2010 3

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5 System Overview The CUBE6 OS system is made up of the following components. All the elements combined will achieve great performance levels with options in the system to increase the performance further Damp Proof Course A Damp Proof Course is rolled out into place on the internal wall before beams are laid. Concrete Beams CUBE6 manufacture a 150mm deep lightweight precast concrete beams suitable for spans upto 5.8m CUBE6 EPS Units The CUBE6 OS system is made up EPS units; CUBE6 Infill Units fit snugly between concrete beams Closure Blocks Concrete closure blocks are used to finish of the row. Damp Proof Membrane The damp Proof Membrane detailing is for guidance only and should be specified and installed in accordance with the manufacturers instructions. Oversheet CUBE6 OS Oversheet is an addition to a new generation of fast, green and economical thermally in-filled suspended beam floors. CUBE6 Oversheet is manufactured from high density EPS which separates the concrete topping from the beam, improving PSI Values and isolating the DPM from the concrete topping, benefiting both the screeders and underfloor heating installers. Perimeter Strips Line the edge of the floor layout, preventing any cold bridging between the interior wall and concrete screed. Structural Concrete Topping The concrete layer, to the following specification completes the system; Domestic Only Domestic & Communal Areas Domestic Only Underfloor Heating Minimum 75mm thick concrete* C25/30 with Fibrin 23 bres, dosage of 0.91kg/m 3 C28/35 self levelling with Fibrin PC12 bres, dosage of 0.75kg/m 3 Minimum 75mm thick concrete* C25/30 with Durus S400 polypropylene macro bre, dosage of 4kg/m 3 (NHBC approved bre) C25/30 reinforced with one layer of A142 mesh with 35mm cover Minimum 85mm concrete* Stapled systems only - minimum 60mm cover over pipes C28/35 self levelling with Fibrin PC12 bres, dosage of 0.75kg/m 3 C28/35 reinforced with A142 mesh with 35mm cover The concrete topping should be accordance with BS8500-1:2015, BS8500-2:2015 & BS206:2013, manufactured in plants covered by the QSRMC scheme and laid by personnel with the appropriate skills and experience. * maximum aggregate size 10mm 5

6 EPS Units CUBE6 OS comprises of 4 main EPS components available in two types of EPS; high performance Platinum EPS in Grey or the standard performance EPS in white: The 4 components are made up of Starter Units, Full units (suitable for nominal 600mm beam centre), half units for reduced beam centres and finished with end units. All units are 1200mm long and can be cut on site to the required length; (minimum 100mm around the floor perimeter edge only). For easy identification each unit has been colour coded within the pack. Starter Unit Full Unit Half Unit End Unit Variable Width Board / Oversheet End Unit / Starter Unit 300mm wide Full Unit 540mm wide Half Unit 270mm wide Variable Width Board 350mm wide x 1200mm long Oversheet 1219mm wide x 2438 long End Units in the CUBE6 OS Infill range are used for both the start and end of the CUBE6 OS unit installation. The starter units are inserted at the start of the run with the straight (1200mm edge) opposite to the beam. The end units inserted at the end of the run are again inserted with the straight (1200mm edge) opposite to the beam. 6

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8 CUBE6 Infill Installation CUBE6 OS Infill units negate the need for concrete blocks, fitting snugly between concrete beams. The units are to be installed from above but with the beam in the precise location intended in the beam layout design. This means less manual handling of beams and a faster installation. End Unit / Starter Unit 300mm wide Full Unit 540mm wide Half Unit 270mm wide min 150 mm void Starter Unit Max 300mm Span (Also used as a End Unit) Variable Width Board Full Unit End Unit Max 300mm Span (Also used as a Starter Unit) External Ground Level Teliscopic Vent CUBE6 OS Infill units are made up of Starter, Full Width, Half and End Units. A Starter Unit can also be used as an End Unit. Variable width boards are used where necessary to complete the row. A minimum of a 150mm void is required below the units to facilitate ventilation to the underfloor through the telescopic vent. Do not walk directly on any CUBE6 Units. Use timber boards to form a temporary working platform. 8

9 1. Starter Units The row starts off with a (White) Starter Unit (Starter Units are also used as End Units) 2. Full Units Dependent on the beam layouts plan either full units (Blue) or half units (Yellow) are then installed 3. Full Unit Offcut The last unit in the row is then cut and used to start the next row. 4. End Units End units (White) are used to finish off the row. (End Units are also used as Starter Units) 9

10 Oversheet & Completing the Floor After all the Units have been installed the concrete closure blocks are inserted (Closure blocks must be of equal strength to the rest of the inner leaf), followed by the perimeter strips a Damp Proof Membrane (if required) and then the Oversheet, finished off with the structural concrete topping. Oversheet can be configured to any CUBE6 OS layout. As per the units, off cuts can be used to start the next row. Installation of CUBE6 Oversheet units must follow the beam design layout. Damp Proof Membrane Oversheet Perimeter strips Concrete Screed Perimeter strips must be a minimum of 25mm for CUBE6 Platinum EPS (Grey EPS) or 30mm for the substantial performance White EPS. Closure blocks must be of equal strength to the rest of the inner leaf. Closure blocks, perimeter strips and structural concrete are not supplied as part of the CUBE6 OS system, however they are important components of the completed floor. 10

11 Gas membrane to lap under cavity tray Perimeter Strip Oversheet Specified Topping DPM (if specified) Perimeter Strip min 150 mm void Starter Unit Max 300mm Span (Also used as a End Unit) Variable Width Board (Cut to suit any T-Beam profile) Full Unit End Unit Max 300mm Span (Also used as a Starter Unit) External Ground Level Teliscopic Vent Configuration Examples Oversheet Grout Infill Between Beams Building Wall Starter Unit Full Unit Half Unit End Unit Starter Unit Full Unit Double Beams Full Unit End Unit 150mm - 180mm 150mm - 225mm Oversheets will be EPS 120 for line loads up to 3 KN/m and EPS 200 for 5kN/m line loads. Oversheet thickness s range between 75mm and 150mm and can be either standard White or Platinum Grade Grey EPS. Double beams are used for supporting walls. 11

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