Rev 19. Guide to the installation of Beamshield Plus and Platinum Beamshield Plus Suspended Floor Insulation

Transcription

1 Rev 19 Guide to the installation of Beamshield Plus and Platinum Beamshield Plus Suspended Floor Insulation

2 CONTENTS Introducing Beamshield Plus Step 1 Beam layout Step 2 Starter units Step 3 Full & Half units Step 4 End units Step 5 Completing a row Step 6 Completing the Floor Perimeter strip, Closure blocks & concrete topping specification Double & Triple beam units Installation of Thicker units Installation - Penetrations Installation - Non-standard units Installation - Ventilation Installation - UFH systems Linear thermal bridging Good practice Loadings Do s & Dont s Health & Safety Page 1

3 INTRODUCING BEAMSHIELD PLUS Beamshield Plus is the fast, green and economical way to insulate suspended T beam floors. This manual will guide you through some of the essential steps to successfully installing Beamshield Plus and Platinum Beamshield Plus units. What is the Beamshield Plus difference? Most other systems are only insulate only some of the beams in a floor and have concrete blocks bridging the beams to the inner leaf. Beamshield Plus has the ability to insulate wall to wall with just environmentally friendly, lightweight EPS. Beamshield incorporates Pre-cut Starter units and End units or alternatively units cut from half units or full units to bridge the gap from first and last beam to the inner leaf with a structurally tested concrete topping to complete the floor finish. Beamshield Plus can accommodate a wide variety of beam configurations based on beams at nominal 600mm and 300mm centres (the exact spacing between beams should be done using Beamshield Plus units). Beamshield Plus also can be supplied in double and triple beam units cut specifically to fit without the need for the pinning of separate insulation pads below beams. Before installing Beamshield Plus we recommend that you read this manual and make an appropriate Method of work template and risk assessment of the work in hand. We also recommend that you read the Beamshield Plus BBA certificate as this contains other useful information. The Technical office at Springvale will be pleased to advise on any questions you may have and their contact number is Example Beamshield Plus Units Half unit Full unit End unit Starter unit Page 2

4 STEP 1 BEAM LAYOUT Correct design of the beam layout is essential and the beam layout drawing must be referred to throughout installation. Do not fix beams into place with closure blocks until all units have been installed. Starter units End units C HALF PANEL C BAY1 HALF PANEL FW C C BAY2 A A Installation of Beamshield Plus units requires free movement of beams; this will also assist with fitting multiple beam units and thicker units. FW BAY3 A A A A C C Avoid placing beams in contact with parallel walls as this may create a cold bridge. 540 Beam spacing for Full units must be 540mm * 270 Beam spacing for Half units must be 270mm* (*Measured from inside corner of beam) Page 3

5 STEP 2 STARTER UNITS FIT STARTER U N IT O NTO FIRST BEAM PO SITION STARTER UNITS AND BEAM TIG H T AGAINST IN NER LEAF It is good practice to begin each bay with a Starter unit. Proceed installing the units in the direction of the toe and continue to the opposite wall. Do not change direction as this could lead to gaps in the insulation envelope. Lay the beam at a slight angle before attaching the starter units, and move the beam closer after each unit is attached Cut line It is possible to create Starter unit (Blue) and End units (green) from one Full unit Page 4

6 STEP 3 STD FULL & HALF UNITS Beamshield Plus units are lightweight and easy to handle. They should be installed with care so as not to be damaged during fitting. We do not recommend that units are walked upon and that spreader boards or planks are used where access is required. Where stepping onto the units is unavoidable then this should be occasional light foot traffic only. All Beamshield Plus units are designed and accurately cut to suit the appropriate beam. Ensure that the correct unit is used in conjunction with the correct beam and that the EPS units are fully supported by the beam shoulders. Installation sequence Installation should proceed in the direction of the toe. Once a unit is positioned ensure that the beams are tightly butted up to the EPS units. Where thicker units are required then the units can be temporarily propped up whilst the next beam is craned and pushed into place. (See pic opposite.) Page 5

7 STEP 4 END UNITS End units are pushed into place from above End units are supplied as pre cut units 300mm in length, or can be cut from Half or Full Beamshield Plus units. Ensure that cutting is done accurately and squarely so the units closely abut the inner leaf. C u t lin e It is possible to create Starter unit (Blue) and End units (green) from one Full unit. Page 6

8 STEP 5 COMPLETING A ROW The final unit in the row must be cut accurately to abut the inner leaf. Do not walk directly on the Beamshield units use timber boards to form a temporary working platform Full unit Cut unit Where possible position the final cut unit against the inner leaf (as diagram) Waste on site can be reduced by using shorter off cuts to complete the row the final piece in a row can be 100mm Care should be taken that these pieces are cut accurately and are not stepped upon before and during the pour Page 7

9 STEP 6 COMPLETING THE FLOOR Perimeter strips, concrete closure blocks and structural concrete topping are not supplied as part of the Springvale Beamshield Plus system, however they are important components of the completed floor. Perimeter strips must be minimum 25mm Springvale Platinum EPS or 30mm white EPS Closure blocks must be of equal strength to the rest of the inner leaf STRUCTURAL CONCRETE SPECIFICATION: Overall Concrete Thickness above the services (mm) Page 8 Grade Maximum aggregate size (1) (mm) Type Reinforcement Specifications 75 C25/30 10 Standard (2) Macrofibre Durus S400 (3) dosage (4) (5) of 4 kg/m C25/30 10 Standard One layer of A142 mesh to BS 4483 Nominal cover to steel 35mm 60 C28/35 10 Standard One layer of A142 mesh to BS 4483 Nominal cover to steel 27mm 75 C25/30 10 Standard 0.91 kg/ m -3 Fibrin X-T 12 19mm Polypropelene micro fibre (6) to BBA 06/ C28/35 10 Self Compacting (7) 0.75 kg/ m -3 Fibrin PC12 Polypropelene micro fibre Class 1 (6) to BS EN : The aggregate for the concrete must comply with BS EN 12620: Specification and workability of the concrete should be selected as appropriate for the intended installation method, in accordance with BS : 2015 and BS EN 206: BBA Certificate of Consistency of Performance 0836 CPR 14/P The minimum residual flexural tensile strength of the macro polymer fibre concrete topping is 1.61 MPa at 0.5mm CMOD and 1.73 MPa at 3.5mm CMOD. 5. Macro-polymer-fibre content should be measured on each site in accordance with BS EN :2007 for fresh and hardened concrete macropolymer-fibre reinforced concrete. 6. Micro-Polymer fibre structural concrete topping is not accepted on NHBC sites. 7. Self-levelling compacting concrete with equal or greater concrete strength can be used (For full specification See BBA Certificate 07/4411).

10 INSTALLATION DOUBLE AND TRIPLE BEAM UNITS Beamshield Plus is unique in offering specially cut double and triple beam units to simply and quickly fit to multiple beam layouts without any cutting and pinning of extra insulation pads. When installing Double and Triple units it is essential that the beams can be moved to facilitate easy fitting. Check that the correct Beamshield Plus unit conforming to the correct beam and beam configuration is used. Page 9

11 INSTALLATION OF THICKER UNITS Thicker Beamshield Plus units can be installed working from the end unit back towards the Starter unit. This makes it easier to position the beams into place. Procedure: Install the starter unit If the row next to the Starter unit is a half unit install this unit next. Accurately measure and set out all remaining beams Cut and install the End unit Install remaining rows working away from the End unit except for the last full unit row. Cut the last full units at an angle (roughly 45 degrees) down the length (see below). Install the section with the toe onto the beam and then install the other section into the space making sure that both pieces are securely supported by the T beam shoulders Page 10

12 INSTALLATION TIPS Detailing It is vital that all gaps caused by cutting the Beamshield Plus unit, particularly around SVP s and other penetrations Beamshield Plus is unique in offering specially cut double and triple are filled use suitable polyurethane expanding foam to fill any gaps. beam units to simply and quickly fit to multiple beam layouts without Trim any excess foam neatly using a sharp knife or saw. any cutting and pinning of extra insulation pads. Penetrations It is important not to create unwanted cold bridges. Pipes should be positioned away from walls and beams, and where possible not less than 50mm to avoid a cold bridge. SVP mm STARTER UNIT HALF UNIT Page 11

13 INSTALLATION TIPS Occasionally where the beam layout drawing and built foundation do not match exactly, problems can arise, particularly where beams clash on sleeper walls. When this occurs it is vital that units are not spoiled by the removal of unit toes etc. Where a non standard spacing is unavoidable it is possible to cut a non standard unit on site using a hot wire cutter and special templates (see photo). Ensure that all appropriate risk assessments and permits are in place before using a hot wire cutter on site. Once all of the Beamshield Plus units are installed and closure blocks are in place it is occasionally required for the replacement of a unit. This can be difficult especially with the thicker units. When this occurs the replacement unit can be installed as shown below: CUT UNIT AT 45 DEGREES INSERT FIRST CUT PIECE INSERT SECOND CUT PIECE Page 12

14 INSTALLATION - VENTS Min. 200mm void Telescopic vents should be used to extend below the level of the Beamshield Plus unit (see diagram above) Min. 200mm void Where the floor design has not allowed for the correct thickness of Beamshield Plus unit, and the vent opening is interfered with by the Beamshield Plus unit, it is possible to cut an opening to facilitate ventilation to the underfloor. The opening must be only the width of the vent itself and must not expose any part of an adjacent beam. Page 13

15 INSTALLATION UFH SYSTEMS Minimum clearance of concrete above pipes is 60mm. Underfloor heating pipes can be accommodated in several ways but in all cases the minimum concrete clearance above the Beamshield Plus units must be maintained. (See page 8 of this guide or our BBA certificate 07/4411 for correct thickness of concrete topping) Where a reinforcing mesh is used UFH pipes can be secured to the mesh. Where there is no mesh then plastic screw fixings can be used to secure the pipes to the Beamshield units. Where a membrane prevents the use of screw fixings then systems incorporating a clip rail or plastic system plate may be used. Always seek manufacturer s advice before specification. No compressible layers of insulation should be used above the Beamshield Plus system. Page 14

16 LINEAR THERMAL BRIDGING GOOD PRACTICE The new Building Regulations 2010 focus attention on heat loss at critical junctions within the construction, and as a result linear thermal bridging values( () are now required to fully assess the energy performance of all new houses. Springvale can provide PSI values for Beamshield Plus junctions to contribute to excellent Y values in SAP The junction below demonstrates good practice in preventing undue heat loss in a Beamshield Plus floor. Beam parallel to inner leaf Starter or Cut End unit Minimum 100mm Perimeter edge strip 30mm Platinum EPS 70 * Closure block 0.19 W/m K Cavity insulation minimum 150mm below beam * Inner leaf below beam 0.15 W/m K (3.6 N) * Foundation block 0.15 W/m K (3.6 N ) Minimum 200mm ventilated airspace below EPS unit * Components not supplied by Springvale The three most critical details in a good junction are the lightweight foundation block and foundation wall, the perimeter strip, and the level of the cavity wall insulation relative to the T beam. Page 15

17 LOADINGS Beamshield plus works in conjunction with a structural concrete topping (specification page 8). The concrete topping spans the T beams and creates the finished floor. The Beamshield Plus system is suitable for domestic floors and also communal areas in flats and offices. It is important that the loadings for the topping are not exceeded. (See table below) Use Loading Domestic and residential Point load of 1.4 kn Uniformly distributed load of 1.5 kn/m 2 together with an allowance of 1 kn/m2 for partitions Line load of 5kN /lin metre from block work both parallel and perpendicular to span of beams Communal areas in flats and offices Point load of 4.5 kn Uniformly distributed load of 5 kn/m 2 together with an allowance of 1 kn/m2 for partitions Line load of 5kN /lin metre from block work both parallel and perpendicular to span of beams * Use the above table in conjunction with the appropriate Beamshield Plus structural concrete topping specification (See page 8 of this guide or consult our BBA certificate 07/4411 Page 16

18 DO & DON T s Always read this installation guide before installing Beamshield Plus for the first time. Prepare the site in accordance with the Beamshield Plus BBA certificate 07/4411and ensure that the ground beneath the Beamshield Plus is free from vegetation. Always ensure that minimum 200mm ventilated airspace is provided beneath the Beamshield Plus units. Where clayheave is expected this should be increased in accordance with NHBC guidelines. Always ensure that vents are installed so that the specified free flow of air to the underfloor void is provided. Always consult the T beam layout drawing before installation. Avoid placing T beams directly against parallel walls, as this will contribute to cold bridging. Do not restrict the free movement of the beams with closure blocks prior to laying the Beamshield Plus units. It is good practice to start each floor with a Starter unit and proceed in the direction of the toe to the opposite wall. Do not change the direction of the toe mid-way in the floor as this could lead to gaps in the insulation envelope. Do not cut off the toes of the Beamshield Plus units in order to fit them to the beams. Avoid walking directly on the Beamshield Plus units and where access is required use boarding or planks. Tamper boards should be used to level concrete where necessary. Limit the concrete pour to a maximum height of 300mm above the Beamshield Plus units and restrict concrete heaps to no greater than 150mm. When fixing a reinforcing mesh use spacers to ensure a minimum 30mm cover to the Beamshield Plus units. Where a membrane is required this must be laid flat above the Beamshield Plus units. Where UFH pipes are installed above the Beamshield Plus units ensure that a minimum 60mm thickness above the pipes is maintained. Always install perimeter strip around the exposed edges of the floor. Always fill * any Use gaps the above with suitable table in polyurethane conjunction foam with filler. the approprate Where Beamshield applicable Plus ensure structural a good concrete floor/wall topping junction specification by following an (See enhanced Page page 16 8 of thermal this guide detail. or consult our BBA cetificate 07/4411 HEALTH & SAFETY Page 17

19 HEALTH & SAFETY Please note that these guidelines are strictly broad based and the information contained is not meant to be exhaustive. It remains the responsibility of the installer to ensure suitable and sufficient risk assessment is undertaken appertaining to the environment of each individual installation. All operatives and their supervisors must ensure safe and practicable controls are maintained and that those persons undertaking installation are trained, authorised and competent in the use of any equipment, tools etc required. This guidance in no way absolves the installer of compliance of local and or national legislation. It remains the responsibility of the installer to ensure such requirements are adhered to. This document is the intellectual property of Springvale EPS Ltd and must not be copied or reproduced without their permission. For all technical enquiries contact our Technical help desk at Glossop For all sales and general enquiries contact our office at Glossop Page 18