Superbead - B&B System Manual

BEAM + BLOCK SYSTEM MANUAL

21 - 23 Shore Road Holywood County Down BT18 9HX T +44 (0) 800 085 6687 info@energystoreltd.com

energystoreltd.com

01

CONTENTS

energystore Company Background

2

Design Considerations

3

Design Guide Considerations Overview

4

Installation Guidelines

5

Important Health Notice

5-6

Installation equipment

6-7

Quality Checks

8

Health & Safety

8-9

Drilling Operation Drill Patterns

10 11-12

Borescope

13

Block & Beam Floor Insulation

14

Property Checks: External

15

Filling the Block & Beam Floor Void: Full Fill

15

Making Good

16

Maintenance of Services

16

Customer Care

17

02

energystore company background energystore has been a manufacturer and supplier of insulation to the building trade for 50 years and holds many accreditations for its products. energystore is the ‘system designer’ and in being so, is the sole supplier of insulation materials to you – as a licensed installer – under our signed agreement.

The system is suitable for use with beam & block flooring systems that use any form of concrete blockwork.

All block dimensions used within the flooring system can be accommodated, including double block depth layouts, provided they can enable a drill pattern that meets the key design principles set out on pages 10-12.

This document covers the design and installation considerations for using energystore superbead® in applications below beam & block flooring in new build domestic construction. The installation method is covered under KIWA Agrement certificate BAF-21-202-S-A-UK and should only be installed by approved installers.

Screed Vapour Control Layer Beam & Block Floor energystore superbead® Damp Proof Membrane

03

DESIGN CONSIDERATIONS Installing energystore superbead® under new build domestic beam and block floor systems can provide a number of advantages to the designer and housebuilder.

When designed correctly this unique system can lead to:

• Reduced overall floor construction depths • Reduced material consumption • Enhanced thermal performance To realise the benefits of the system, the following design considerations should be taken into account. In addition to the design considerations outlined in this document, the designer and housebuilder should take care to ensure that all Regulatory requirements are adhered to.

Thermal Performance Considerations All new build construction sites are required to comply with local Regulations on the conservation of fuel and power.

Based on the overall building design requirements, the depth of void for energystore superbead® beneath the beam & block floor should be designed and constructed prior to installation to achieve the floor U-Value requirement.

Declared Thermal Performance of energystore superbead® - 0.033 W/m/K Illustrative floor U-Values for the energystore superbead® beam & block system are outlined below for guidance.

Void beneath Beam

P/A Ratio 0.25

0.30

0.35

0.40

0.45

0.50

Site Specific Considerations

150mm

0.12

0.12

0.13

0.13

0.13

0.14

There will be unique geographic considerations at each site which must be considered when designing the floor construction. The considerations which are specifically relevant to the use of the energystore superbead® beam & block system are outlined below:

175mm

0.11

0.11

0.12

0.12

0.12

0.12

200mm

0.10

0.10

0.11

0.11

0.11

0.11

225mm

0.093

0.096

0.99

0.10

0.10

0.10

250mm

0.087

0.090

0.092

0.094

0.096

0.097

1

Sites with no specific flood risk or gas prevention requirements – if the proposed site has been shown to have no specific flood or gas prevention considerations, the design can proceed to thermal performance considerations and installation methodology.

2

Flood Plains * – if the proposed site is on a flood plain or deemed to have considerable risk of flooding, we do not recommend the use of this system unless other flood prevention measures are used. Local Planning and the Environment Agency should be contacted regarding further information on flood risk

3

Radon / Ground Gases * – if the site is in an area with no Radon or ground gas requirements, no specific gas treatment is required. If the site requires Radon or Ground gas protection, please contact our technical team with the site details on technical@energystoreltd. com. We have an extensive range of design details to enable Building Regulation compliance in accordance with BS 8485 and BR 211.

* Flood plain and Gas considerations are outside of the scope of KIWA Agrement certificate BAF-21-202-S-A-UK

In addition, the system can offer enhanced thermal bridging (Psi-Value) detailing. If you require site specific U-Value or Psi-Value calculations, please get in touch with our technical team on technical@energystoreltd.com.

04

Design Guide Considerations overview

Is the site on a flood plain?

YES

Consider alternative floor options

NO

Does the site have Radon / Gas considerations?

NO

YES

Contact energystore for design detail

Set floor depth based on U-Value requirement

Proceed to installation methodology

05

Installation Guidelines

IMPORTANT HEALTH NOTICE

The Installer’s Relationship with KIWA BDA

Pentane is heavier than air and will settle at lower levels.

KIWA BDA agrément certificate: BAF-21-202-S-A-UK

energystore’s Responsibilities It is energystore’s responsibility – as the system supplier – to advise, support and develop a working relationship with all installers in order to help them provide the safest and best quality service to all customers at all times. energystore will provide the approved and certified system methodologies, support and updates on an on-going basis to all approved installer companies from inception of agreement to termination.

energystore undertakes to:

• Provide training, approval and on-going

monitoring of technicians.

• Issue identity cards to approved installers,

valid for 2 years.

• Ensure that all approved installation companies

and their technicians comply with all certification and all other industry requirements.

• Undertake agreed inspections either with or

without notice. (This will usually be on a frequency of between 10 to 15 week cycles, and usually four per annum, or as necessary).

Bonded Bead Product Range energystore superbead Cavity Wall Insulation - 0.033 ʎ energystore superbead Block & Beam Insulation - 0.033 ʎ

e.g. walking/head height in a silo area.

It is therefore essential to ensure the silo area is well ventilated at all times.

As a precaution we would suggest that if you have had a delivery say on a Friday, and the store is closed up for the weekend, you make sure on Monday morning to open all doors and switch on fans to circulate fresh air as quickly as possible. Should you feel ill or unwell vacate the area immediately and inform others.

Adhesive Product Range The range of energystore adhesives are individually designed to work with each of the bonded bead types available. Installers are required to use only the adhesive supplied by energystore.

To get an effective bond it is essential you use the correct adhesive designed specifically for the bead product you order.

NOTE: Protective eyewear should always be used when installing bonded energystore superbead®. The adhesive can cause damage to the eye and should be immediately treated with water in the event of entering the eye.

Storage of Adhesives and Directions for Use

• Do not allow the adhesive to freeze.

• Keep out of direct sunlight.

• Store all adhesive at between 5-25˚C. • Only use approved adhesive and use in

accordance with energystore training.

•

The adhesive is filtered through the delivery system CHANGE.

• Specialised adhesives containing antifreeze

components are available for use in winter and extreme cold conditions. energystore advise using this adhesive when working conditions remain below 5°C.

06

• Adhesive must not be allowed to freeze or sit in

System Manual

Buildings Under Construction

Block & Beam Floor Insulation Injection Machinery

sunlight; precautions must be taken to store materials in a frost free environment. Batch numbers must be taken and noted to allow for accurate traceability and the expiry date must not be exceeded.

NEW BUILD SURVEY FORM

• A New Build Survey Form is to be completed before

any install works and must detail: site location and plot number, void depth, borescope locations, services under the floor, membrane installed, superbead and glue batch numbers.

This installer manual should be carried on site by all installers and be available at all times. It sets down measurable standards and routines to ensure quality and professionalism.

The block and beam floor insulation injection machinery system has to be regulated in order to achieve all relevant certification body approval.

Any changes to the installation system used by a registered installer must be approved before being put into use on site.

• Following installation, the entire floor must be

All approved installation system machinery should bear a registration plate which is specific to the install system and underfloor insulation product being used.

• It is essential that screeding is not started before

All underfloor insulation systems and injection machines must operate in strict accordance with the system specification and KIWA BDA certification.

sealed to accept the screed finish.

the superbead underfloor installation is complete.

• The drill pattern used will follow as per a block pattern

(medium or dense blocks), where all holes are drilled into the joints between the blocks.

KIWA BDA The installation system described in this manual, together with all material recommended for block and beam floor insulation have been tested and approved by KIWA BDA. The materials and\or system of installation described should NOT be altered. All approved operations and policies and their cautionary procedures exist for the safety of the property occupier, the customer, installers and members of the public.

Agrément Certificates: Certificate Number BAF-21-202-S-A-UK

Compressors

This Agrément Certificate Product Sheet relates to energystore superbead® block & beam floor Insulation, expanded polystyrene material injected in bead form with a bonding agent, for use in internal masonry block & beam floors, with nominal voids beneath the beam not less than 100mm.

Compressors should be of a suitable capacity to deliver the required psi/bar as stated by the system designer.

This will vary depending on:

• The number of delivery hoses attached to

Installation equipment The following is a comprehensive list of equipment and accessories required by all installers of block and beam floor insulation.

the compressor.

• The operating lengths.

• The distance from the truck.

The compressor should operate at a working pressure of 7bar maximum.

07

Installation equipment Adhesive

Bead Delivery Hose

Adhesive must be fed through a flexible hose to the rear of the injection gun, then through a jet sprayer which sprays a fine coating of adhesive over the beads before they are pumped directly into the void under the block and beam floor, using the suggested operating pressures as per the flow rate chart.

This is usually 38mm (internal) diameter with a coiled Helix anti-static reinforcing, to earth any electrical charges.

The hose has a smooth inner facing.

Table of flow rates Bead flow (KG/min )

Floor voids 100mm +(ml per min)

0.6

100

0.7

110

0.8

120

0.9

130

1.0

140

1.1

150

1.2

160

1.3

170

1.4

180

1.5

190

1.6

200

1.7

210

1.8

220

1.9

230

2.0

240

To find the Adhesive Flow Rate per Minute open valve to jet and establish a fine, steady spray of adhesive and collect in an accurate measuring cylinder for a period of one minute.

Compare flow rate with chart and adjust accordingly. This check should be performed when using both the standard and winter grade adhesive products.

REMINDER Protective eyewear should be worn when performing Adhesive Flow rate checks.

Airline Hose Airline hoses are a 12mm reinforced piping and convey high pressure air from the compressor to the regulators, the control valves and the head of the gun (also known as the venturi chamber).

Adhesive Line The adhesive line conveys the adhesive from the glue chamber to the delivery gun. The line is usually between 6mm and 10mm in diameter.

Delivery Gun The preferred internal construction of the delivery gun is always of steel or aluminium. The delivery gun has a diameter of 22mm or 26mm. Nozzles available in various lengths to suit different thicknesses of blocks. The pre delivery area is also known as the ‘Venturi’. Essentially it is the area where the bead is mixed with the adhesive to form a bonding blend which will then cure and set in the floor void.

Adhesive Flow/Regulation Materials Quality Control Records must be kept of delivery of adhesive and bead from the suppliers, and must include the following:

The adhesive flow is controlled by adhesive injection jets. These are available in a variety of sizes and can be interchanged to regulate the adhesive flow without compromising the air pressure flow.

• Date of receipt.

• Batch/product number.

• Quantity delivered and container size.

• Quality checks that were made on each

product and any action required.

Operating Pressure The system is designed to operate at a safe maximum pressure. Preset safety valves must also always be fitted during operation.

The maximum pressure for delivering the two main products is for:

• Bead delivery 7 bar.

• Adhesive delivery 5 bar.

(May be regulated to adjust flow rate)

08

QUALITY CHECKS

HEALTH & SAFETY

Factory Quality Control

It is the responsibility of all installers and their employees to ensure that they are working in accordance with the Health and Safety at Work Act at all times.

Factory quality control is in place to ensure that the size and density of all bead products matches the required specification and that installers’ equipment is operational in accordance with the energystore system manual.

This involves:

• Checking the diameter of bead by passing

samples through a graded series of sieves.

It is the duty of every employer – as far as is reasonable – to ensure the health and safety of every employee. It is also the responsibility of every employee to take reasonable care of their own safety.

All employees must make themselves aware of the company’s Health & Safety policies and procedures at all times.

• Checking the density of bead by filling a vessel

with dry bead and then weighing the contents hourly during production process.

Protective Clothing & Equipment Installers are required to have the following available to them at all times on site:

Installation Equipment Tests Installer equipment is inspected daily prior to commencement of work and the results of these inspections recorded – flow rate, bead weight/density.

Flow rates calculated by filling a hessian bag with dry bead for 30 or 60 seconds, bead is then weighed and recorded.

Bead density is determined from the dispatch information associated with the material being used.

Select from the table the appropriate adhesive flow rate (AFR) in accordance with the flow rate of the bead and density (DBD) of the bead being used. Ratio of adhesive to bead must be correct, to ensure this a bead flow rate check should be carried out and the flow rate of adhesive adjusted to suit, see energystore table of flow rates bead/adhesive.

The pump is charged with adhesive and all interconnecting lines and pipes are fitted. Compressor is started and adhesive pump is pressurised to 5 bar.

• Gloves (anti-white finger gloves for drillers) • Hard hat • Reflective tabard/Jacket/Coat leggings • Appropriate dust mask • Ear defenders • Disposable gloves • Hand wash/barrier cream • Protective footwear • Protective eyewear

09

HEALTH & SAFETY Installation Equipment

• Ensure all those operating any equipment on site

have had the appropriate training.

• Take special care when moving equipment and

materials in order not to put yourself or others at risk.

• Be sure to disconnect the power supply when

not using electrical equipment.

Employers Responsibility It is the employer’s responsibility to ensure all staff are trained and have a good working knowledge of any equipment they are required to operate. The employer must also ensure that all staff have had adequate Health & Safety training to protect their wellbeing and that of other team members, other trades persons and customers.

Handling Materials

• Wear protective clothing at all times when

handling materials.

• Never strain or expect others to risk injury.

• Whenever possible spread the load with colleagues

when moving heavy materials or equipment.

Drilling

• All drilling must be undertaken in a safe manner

and with due care to the property, making sure the inner section of block floor is not shattered by drilling with excessive force.

• Check that no cables or pipes are present to

prevent drilling through them.

• Use a depth stop on the drill.

Compressed Air

• Ensure the compressed air is controlled and

conveyed through the recommended equipment.

• Make sure all hoses are in good order, free of cracks,

splits and fractures.

• Replace any damaged hoses and/or

connections immediately.

• Check safety valves at least once a week.

• Check the compressor’s operation every week.

• Use only correctly sized couplings/connections.

• Only qualified employees should operate

the equipment.

• Only operate the equipment in line within the safe

or recommended maximum pressure.

Hoses & Cables Where hoses and cables cross pedestrian routes, display warning notices and make a simple footbridge to avoid leaving a trip hazard.

10

DRILLING OPERATION Types of Drill: Electric 110v powered drills.

Drill Points

Drill holes must be sized between 22-26mm.

• Drill holes should be made in mortar joints.

• Do not drill through floor beams.

• Take care around building features without

• Usually drill 300mm in from wall perimeter.

• Always use quality sharp drill bits.

• Drill with light pressure to minimise debris

falling into floor void.

• Drill holes vertically – not at angles.

• Allow a maximum of 900mm of space between

drill holes around perimeter of floor.

• Drill between 200-300mm around any

•

obstruction in the floor.

All drilling should only go to a depth of 10mm

more than the thickness of the blocks being

used to create access.

causing damage to blocks.

Filling must not commence until such time that the floor has been completely drilled out.

11

DRILL PATTERNS Set out below are a series of illustrative drill patterns to ensure a successful fill of the underfloor void using energystore superbead®. Block & Beam floor layouts that are not shown below are still possible providing they can allow a drill pattern design which follows the key principles.

3

The 1st drill hole in each row should be 300mm max from the wall.

4

There should be a 900mm max gap between drill holes in each row of blocks.

The key design principles are:

5

Additional drill holes should be drilled around any services or obstructions at 200mm max apart.

1

Each row of blocks within the floor layout should have drill holes.

2

The pattern design should aim to have as many of the drill holes on the joint between blocks as possible.

It is acceptable to drill through blocks, however, it is recommended to drill through the joints wherever possible. DO NOT DRILL THROUGH THE BEAMS.

Illustrative Drill Pattern for full Width (440mm) B&B Floor

Additional holes should be drilled 200mm max apart around any obstructions running under the floor or protruding through it.

Standard drill pattern, 1st row 300mm max from wall, then 900mm max apart in every block run.

12

DRILL PATTERNS Illustrative Drill Pattern for Narrow Width (215mm) B&B Floor

Standard drill pattern, 1st row 300mm max from wall, then 900mm max apart in every block run.

Illustrative Drill Pattern for Alternating Wide and Narrow Width B&B Floor

13

BORESCOPE Borescope inspections must be carried out to verify the existence of a membrane being installed below the floor.

A least 2 borescope inspections must be carried out per room with a minimum of 8 per property to ensure the membrane is present and there are no visible signs that indicate the membrane wasn’t installed correctly. Location of borescope holes must be recorded on the pre-installation survey form. Site agent must sign the New Build beam & block under floor insulation survey form to confirm the beam and block floor has been built to applicable regulations and standards, the correct membrane has been fitted and inspected during construction.

Typical Section Detail and DPC / Membrane Locations Typical section detail is outlined below. The key principles of membrane design is to minimise interstitial condensation and ensure resistance to moisture are as follows: 1

A Damp Proof Membrane (DPM) installed between energystore superbead® and the ground. The DPM should continue up the inner leaf and be secured beneath the beam & block floor system.

2

A Vapour Control Layer (VCL) should be installed between the final screed and the beam & block floor system.

DPC / Membrane details for prevention of ground gases can be provided by our Technical Team if required.

Please contact technical@energystoreltd.com for further guidance. Gas membrane detailing is considered outside the scope of KIWA Accreditation.

Sand/Cement Screed Vapour Control Layer Suspended Block and Beam

energystore superbead® Damp Proof Membrane

14

Block & beam floor insulation Pre-Installation Building Assessment and Survey The following checks must be made and recorded on the new build survey form prior to the commencement of all block & beam insulation works:

• Building must be surveyed to ascertain its suitability

for under floor insulation.

• Is the floor of block and beam construction, what

block type has been used?

• Has a High Performance Damp Proof Membrane,

suitable for use in ground floor constructions below ground, been installed below the floor?

• A minimum of 2 borescope inspections per room and

minimum of 8 per property must be carried out and the void/cavity depth must be clearly recorded on the survey sheet. The void depth recorded on the survey sheet should be taken as an average of all measurements taken. The void/cavity should be a minimum depth of 150mm from the bottom of the block. For the purpose of As-Built U-Value calculations the measurement is taken from the underside of the beam.

• Identify locations of any services running in the void

below the floor (record on survey form).

• Go through all the details of the property assessment

The membrane should be installed to the manufacturers specification and should include: 1

2

3

4

5

Should be installed on a smooth continuous compacted surface, the substrate should be free irregularities such as voids or protrusions.

Have sealed laps of at least 150mm wide, bonded with a jointing tape to the manufacturer of the DPM’s specification.

Link with wall DPC’s to form an imperious barrier to prevent moisture reaching the interior of the dwelling.

Air tight seals should be formed around service entry points to the manufacturer of the DPM’s specification.

Take account of possible differential movement.

Suitable materials for DPM’s include: 1

1200 gauge (0.3mm polyethylene sheet).

2

Bitumen sheet to BS6398.

3

Minimum 1000 gauge (0.25mm) polyethylene sheet where it complies with Technical Requirement R3.

4

Materials that comply with Technical Requirement R3.

Is the floor dry? Do not install if pooling water is present or the floor is damp.

•

form with the site agent explaining procedures, checks and tests required.

• If the membrane is damaged or incomplete repairs

must be carried out as per the technical requirements of the membrane manufacturer.

CHECK depth of void below floor, does it match your job card?

If the void is larger or smaller than specification provided STOP do not proceed until a change to the specification has been agreed by the client in writing.

CHECK has the site representative signed the Pre-installation survey to confirm the membrane has been installed to specification.

STOP do not proceed if this cannot be confirmed.

CHECK has the builder confirmed the design meets the Radon & Gas requirements as per per BS 8485 & BR 211?

STOP do not proceed if this cannot be confirmed.

CHECK Has the membrane been installed correctly (where practically possible).

If the membrane is missing, damaged or incomplete repairs must be carried out as per the technical requirements of the membrane manufacturer before works commence.

CHECK drains, waste pipe and cable runs.

It is vital these are checked before installation to avoid any damage and again after the installation is completed, any possible damage must be reported to the site agent.

STOP do not proceed if this cannot be confirmed.

15

property checks: external Why are external checks necessary?

• To ensure the installation is carried out to an

acceptable and approved specification without damage to the property or exposing any individuals to health and safety risks.

• To confirm the property is suitable to for

underfloor insulation.

Installers on site, prior to commencement of the installation works must:

• Double check the initial assessment. Is there anything

unusual or different from the details provided on your job card? (property size).

• Confirm that the property is watertight (roof installed).

• Carry out a hazard awareness assessment; even if

one has already been undertaken - conditions may have changed.

Filling the block & beam floor void: Full fill The Drilling Operation

• The drilling out of a property commences using the drill

pattern agreed, through the joints where floor blocks

meet – to the area to be insulated. It is possible to drill

through the block if required, however, it is

recommended to drill through the joints wherever possible. (DO NOT DRILL THROUGH THE BEAMS)

• Care is taken with the laying of delivery hoses from the

delivery truck to the property. Where necessary, step-over ramps are put in place to safeguard pedestrians and/or customers and installers from

falling. HAZARD SIGNS are also deployed in order to

make people aware.

• Ensure all drill holes are fitted with a cavity barrier

brush once all holes have been drilled.

Start the Filling Operation Prime flow lines.

• Once the drilling operation has been completed and

fitted with cavity barrier brushes, complete the flow test making sure the flow rate meets the required specification. Remove the cavity barrier brush from each drill hole one at a time and commence the installation starting at the injection points around any obstructions, then follow the approved sequence.

• Insert the nozzle of the injection gun halfway into the

block (use correct length nozzle and depth stop on injection gun) When each void is full, back pressure will stop the flow of bead (this is seen through the clear section of hosing that connects directly to the gun).

The adhesive valve must now be immediately closed if installing the system bonded.

End of Operation Once the adhesive valve is closed:

• Disconnect and remove all hoses.

• Tidy around the site.

• Point all drill holes as necessary.

• Carry out visual checks to any pipes or cables

for damage.

• Remove all remaining equipment, signs etc.

• All installers on-site should inspect the work

and then make a final inspection with the customer.

• Invite the customer to sign off the completed job.

• Make detailed notes including batch numbers

for adhesive and bead.

16

Making good

MAINTENANCE OF SERVICES

It is of the utmost importance that ‘making good’ is done to as high a standard as possible, leaving the property in as good order as possible to minimise the impact of the works on the following trades.

All services to be placed underneath the floor should be installed prior to installation of energystore superbead®.

In the unlikely event that the services need to be maintained or altered after installation of energystore superbead®, please contact the installation company to advise of any remedial work required to the insulation.

Remember: Good practice is the best advertisement for creating future business.

• Obtain mortar from site silo or mix mortar,

using a bucket, cement, sand, water and a trowel.

• Sweep to remove any loose insulation material

or drill dust.

• The mortar should be moulded into a sausage shape

and then worked into the drill hole and finished to match the surrounding floor.

Final Checks

• Bead ingress. Remove any bead found immediately.

• Check that all drill holes are filled, no tools remaining.

• Check that all dust has been swept up from

all floor areas.

• If any remedial treatment is required, ensure

it is recorded and reported for action at the earliest opportunity.

• The site must be left clean and tidy as found.

Customer Sign Off Check that your customer is totally happy and satisfied with the installation work and then ensure that they sign off the job as being complete.

Minor adjustments to the services are unlikely to cause any disruption to the insulation layer. However, where the insulation has been removed, an approved installer can refill any voids created using the installation guidelines outlined above.

If the maintenance of services requires disruption to the membranes, floor screed or beam & block flooring system, guidance should be sought from the manufacturers of those products to ensure the flooring system continues to achieve the necessary performance levels.

17

Customer care Customers are Individuals

• Each customer has specific needs, desires, concerns

and expectations which must be respected and handled with understanding and good manners.

• Be sure you understand your customer’s

expectations in order to avoid issues later.

• Be polite at all times. Do not be over familiar or too

friendly, as this may cause offence.

• Be professional at all times.

• Explain what you are doing and why, to keep the

customer informed and happy.

• Give them the opportunity to air their concerns before

commencing any works. It will save you time and trouble later.

• If you think you are going to have a procedural

problem, bring it to the attention of the customer as soon as possible, discuss options and agree a way forward, noting on the job card the deviation and agreement reached.

• Note all reasons for, and changes to, standard

procedure taking photographs and recording details of the agreement reached with the customer and the final outcome. Also include the testimony of any colleagues present.

• Ensure that your actions are always in the customer’s

best interest.

• Always encourage the customer to inspect and sign

off completed installation work, noting any changes, agreements and comments plus further works agreed.

• Always get a customer signature of satisfaction.