Polyfoam Floorboard - SIG Insulation Floorboard.pdf · Polyfoam Floorboard is a high performance,...

DescriptionPolyfoam Floorboard is a highperformance, 100% ozone friendly,extruded polystyrene, rigid boardinsulation. It is lightweight, yet hasexcellent structural strength and long termeffectiveness.

Polyfoam Floorboard is available in 3grades to suit the intended end use of thefinished floor:

• Standard – General Domestic LoadFlooring

• Extra – Commercial, Industrial Flooringand Cold storage

• Super – Very High Load Commercial,Industrial and Cold Storage floors

Polyfoam Floorboard Super is suppliedwith interlocking rebated edges. PolyfoamFloorboard Standard and Extra are squareedged boards.

ApplicationPolyfoam Floorboard is used for thethermal insulation of floors. In flooringinsulation, the optimum solution has to:

• be strong• have low moisture absorption• be a good thermal performer• be structurally stable in the long term• be lightweight• be easy to install

The following range of applications aresome of the key areas of use of PolyfoamFloorboard:

• General domestic load flooringHousingOfficesSchoolsHospitals

• Commercial load flooring Heavier load offices, schools and HospitalsFactory and industrial units

• Cold Store floors

• Basement Walls

Polyfoam Floorboard is suitable for almostany floor construction including:• Below a concrete slab• Below screed on a beam block

suspended floor• Below screed on a ground bearing

concrete slab• Below screed on an upper/intermediate

concrete slab floor• Below chipboard on a beam and block

floor• Below chipboard on a ground bearing

concrete slab• Below chipboard on an upper/

intermediate concrete slab floor• Under a raft foundation

www.knaufinsulation.co.uk Technical Support tel: 01744 693885 fax: 01744 693882 E-mail: [email protected]

Polyfoam FloorboardFor thermal insulation of floors

Product Data Minimum Design Loads1 Water Continuous

Nominal Thermal performance compressive Long term Occasional vapour Moisture serviceThickness Length Width density Conductivity Resistance strength static load loading resistance absorption temp limits (mm) (mm) (mm) (kg/m3) (W/mK) (m2K/W) (KPa) (KPa) (KPa) (MNs/gm) (by vol.) (ºC)

Polyfoam Floorboard Standard

75 2438 600 30 0.029 2.55 200 40 66 480 0.3% -50 to +75

65 2438 600 30 0.029 2.20 200 40 66 480 0.3% -50 to +75

50 2438 600 30 0.029 1.70 200 40 66 480 0.3% -50 to +75

35 2438 600 30 0.029 1.20 200 40 66 480 0.3% -50 to +75

25 2438 600 30 0.029 0.85 200 40 66 480 0.3% -50 to +75

Polyfoam Floorboard Super

100 1250 600 42 0.034 2.90 500 100 166 600 0.3% -50 to +75

75 1250 600 42 0.031 2.40 500 100 166 600 0.3% -50 to +75

50 1250 600 42 0.029 1.70 500 100 166 600 0.3% -50 to +75(1) Design loads by calculated methods.

Polyfoam Floorboard Extra

100 2438 600 38 0.034 2.90 350 70 116 600 0.3% -50 to +75

75 2438 600 38 0.031 2.40 350 70 116 600 0.3% -50 to +75

65 2438 600 38 0.031 2.05 350 70 116 600 0.3% -50 to +75

50 2438 600 38 0.029 1.70 350 70 116 600 0.3% -50 to +75

35 2438 600 38 0.029 1.20 300 60 100 600 0.3% -50 to +75

25 2438 600 38 0.029 0.85 300 60 100 600 0.3% -50 to +75

Strong Waterresistant

Versatile Lightweight Ozonefriendly

Recyclable



PerformanceCompression resistanceAll materials are compressed under load.Insulation materials used in floors shouldbe capable of accommodating theapplied loads with the minimum ofcompression. Polyfoam Floorboard ishighly resistant to compression andwithstands both occasional and long termstatic loads. A factor of safety for designloads of 3 (5 for long term static loads) isapplied to the compressive strength of theproduct as outlined in the product datatables.

Moisture resistanceThe attached detail drawings outline thecorrect position of Polyfoam Floorboard.As can be seen in some constructions, themoisture resistance of the board allows itto be laid exposed to ground water, withnegligible impact on performance. Theboard will not provide a water vapourcontrolling layer, however, it can be laidin ground water or up against wetconcrete. Once in position it will not allowmoisture to cross through the completedconstruction.

Thermal insulationPolyfoam Floorboard is a highperformance insulant, with aged quotedthermal performance values. Unlike mostother insulants, the effect of moisture onperformance is negligible.

The actual performance in use of eachgrade of Polyfoam Floorboard is outlinedin the attached application sections.

Fire PerformanceWhen Polyfoam Floorboard is installed ina concrete or timber floor construction itwill not contribute to the developmentstages of a fire.

CertificationPolyfoam Floorboard Standard, Extra andSuper are third party certified by theBritish Board of Agrément.

Handling andStoragePolyfoam Floorboard is supplied inpolythene packs, labelled with identifyingproduct and manufacturing data.

The boards are easy to handle and non-irritant, no special protective clothing isrequired to install them.

Polyfoam products should not be leftexposed to prolonged sunlight as this willresult in surface degradation. Whereoutside storage for extended periods isrequired cover with opaque/lightcoloured sheeting.

Ensure the boards are not stored close toopen flame or other ignition source, alsoavoiding volatile organic compounds andchemicals such as solvents.



U-values of concrete ground floor slab insulated with PolyfoamFloorboard Standard

U-values (W/m2K)

Product Thickness Ratio of perimeter (m) to area (m2)

(mm) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

75 0.12 0.17 0.19 0.21 0.22 0.22 0.23 0.23

65 0.12 0.18 0.21 0.22 0.23 0.24 0.25 0.25

50 0.13 0.19 0.23 0.26 0.27 0.28 0.29 0.29

35 0.14 0.22 0.26 0.30 0.32 0.33 0.34 0.35

25 0.15 0.23 0.29 0.33 0.36 0.38 0.39 0.40Note: The U-values have been calculated using BS EN ISO 13370: 1998 and assume a clay subsoil with a thermalconductivity of 1.5 W/mK.

PolyfoamFloorboardStandard

InstallationInsulation below concreteslabPolyfoam Floorboard is laid directly overblinded hardcore. The sand blindingshould be level, to receive the insulationboards. Polyfoam Floorboard is laid in astaggered pattern over the whole floorarea. The joints should be tightly butted.

A strip of insulation, minimum 25mm thick,should be placed vertically at the slabperimeter to minimise thermal bridging.Ensure these perimeter insulation boardsare securely held in place to preventdislodgement by following work.

The damp proof membrane is laid overthe insulation and laps with the wall dpc.When placing the concrete floor, spreaderboards should be used as necessary toprevent point loads puncturing the dpm.

The concrete slab may be screeded oralternatively have a power float finish.

This construction is also suitablefor basements.

25mmPolyfoam

FloorboardStandard

Concreteground

floor slab

Dampproof

membrane

PolyfoamFloorboardStandard onsand blinding

Wall insulationto extend atleast 150mmbelow floorinsulation



Wallinsulationto extendat least150mmbelow floorinsulation

25mmPolyfoam

FloorboardStandard

Concrete groundfloor slab

Damp proofmembrane

Polyfoam FloorboardStandard on sand

blinding

Concrete slab or beam andblock floor with a floatingscreedPolyfoam Floorboard is covered by awaterproof membrane/separating layeron which is laid a minimum 65mm thickreinforced sand/cement screed. PolyfoamFloorboard is suitable for use with thinner,non-standard thickness liquid screedsbased on specification advice from thescreed supplier.

Polyfoam Floorboards can be used on abeam and block suspended concrete floorthat is the subject of current AgrémentCertificate and installed in accordancewith, and within the limitations imposed bythe certificate. The surface of any floorshould be smooth and flat to within 5mmwhen measured with a 3m straight edge.Provided the surface is smooth and levelthe insulation may be laid directly onto theflooring system. Otherwise lay a thinlevelling screed (this may be the grout withbeam and block systems) prior to layingthe insulation. Irregularities greater thanthose detailed above must be removed.

A minimum 25mm thick vertical piece ofPolyfoam Floorboard, the full depth of thescreed, should be placed around theperimeter of each room to minimisethermal bridging. Ensure these perimeterinsulation boards are securely held inplace to prevent dislodgement byfollowing work.

The slip layer is laid over the insulationand turned up at the junction with thewalls. If the project is a refurbishment andsecondary damp proofing is required thisslip layer becomes the damp proofing asin a concrete slab construction. In atraditional screed, the screed is laid withthe wire mesh placed at half the screeddepth. It is important to compact thescreed well to produce a durable floorsurface.

U-values of beam and block ground floor insulated with PolyfoamFloorboard Standard

U-values (W/m2K)


(mm) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

25+65 0.15 0.19 0.21 0.22 0.23 0.24 0.24 0.24

75 0.17 0.21 0.24 0.25 0.26 0.27 0.28 0.28

65 0.18 0.23 0.25 0.27 0.29 0.30 0.30 0.31

50 0.19 0.26 0.30 0.32 0.34 0.35 0.36 0.37

35 0.22 0.30 0.35 0.38 0.41 0.43 0.44 0.46

25 0.23 0.33 0.40 0.44 0.48 0.50 0.52 0.54Note: The U-values have been calculated using BS EN ISO 13370: 1998 and assume a dense infill block between concrete beams.




Typical U-values of 150mm concrete upper floor with 65mm screedfinish insulated with Polyfoam Floorboard

Product Thickness (mm) U-Value (W/m2K)

Polyfoam Floorboard Standard 75+35 0.24

75 0.34

65 0.38

Polyfoam Floorboard Extra/Super 75+50 0.23

100 0.30

75 0.36Notes: The U-values have been calculated to BS EN ISO 6946:1997.

Screed orchipboard

Isolatingmembrane

PolyfoamFloorboard

Suspendedconcrete floor

Ventilatedsub floor

25mmPolyfoamFloorboardStandard

Wall insulationto extend atleast 150mmbelow floorinsulation

Concrete upper floors with afloating screedThe insulation should be laid over thewhole of the concrete floor. PolyfoamFloorboards can be used on a beam andblock suspended concrete floor that is thesubject of a current Agrément Certificateusing the procedure outlined above.

The perimeter insulation boards are cut tosize and placed against the wallperimeter.

The vapour control layer is laid over theinsulation and turned up at the junctionwith the walls. The screed is laid, with thewire mesh placed at half the screeddepth. It is important to compact thescreed well to produce a durable floorsurface.

Flooringgradechipboard

Vapourcontrollayer

Wallinsulationto extendat least150mmbelow floorinsulation



U-values of concrete ground floor slab insulated with PolyfoamFloorboard Standard

U-values (W/m2K)


(mm) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

75 0.12 0.17 0.19 0.21 0.22 0.22 0.23 0.23

65 0.12 0.18 0.21 0.22 0.23 0.24 0.25 0.25

50 0.13 0.19 0.23 0.26 0.27 0.28 0.29 0.29

35 0.14 0.22 0.26 0.30 0.32 0.33 0.34 0.35



Insulation below chipboardin floating floor on aconcrete slab or beam andblock floorPolyfoam Floorboard Standard is laiddirectly on the concrete floor and overlaidwith t&g flooring grade chipboard.

The insulation should be laid over thewhole of the concrete floor. The surface ofthe floor should be smooth and flat towithin 5mm when measured with a 3mstraight edge. Irregularities greater thanthis must be levelled out. Where a beamand block floor has a camber or unevenupper surface a levelling screed isrecommended.

Where there is a risk of moisture fromdrying out of the floor slab, a vapourcontrol layer should be used. The vapourcontrol layer is laid over the insulation andturned up at the junction with the walls.

The chipboard is laid in a staggeredpattern with all joints glued using awaterproof PVA adhesive. Leave anexpansion gap of at least 10mm or 2mmper metre run of floor at the roomperimeter. At doorways or access traps topipework runs the cut edges of chipboardshould be supported on preservativetreated battens.

Sand blindingon hardcore

Damp proofmembrane

Concretefloor slab

PolyfoamFloorboard

18mm flooring grade chipboard

Vapour control layer

Polyfoam Floorboard

Concrete floor slab



Typical U-values of 150mm concrete upper floor with 18mm chipboardfinish insulated with Polyfoam Floorboard

Product Thickness (mm) U-Value (W/m2K)

Polyfoam Floorboard Standard 75+35 0.23

75 0.33

65 0.37

Polyfoam Floorboard Extra/Super 75+50 0.22

100 0.29

75 0.35

50 0.45Notes: The U-values have been calculated to BS EN ISO 6946:1997.

Concrete upper floors with afloating chipboard deckThe insulation should be laid over thewhole of the concrete floor. PolyfoamFloorboards can be used on a beam andblock suspended concrete floor that is thesubject of a current Agrément Certificateusing the procedure outlined above.

The vapour control layer is laid over theinsulation and turned up at the junctionwith the walls. The chipboard is laid in astaggered pattern with all joints gluedusing a waterproof PVA adhesive. Leavean expansion gap of at least 10mm or2mm per metre run of floor at the floorperimeter. At doorways or access traps topipework runs, the cut edges of chipboardshould be supported on preservative-treated battens.



Reinforced concrete floor slab

Polyfoam Floorboard

Damp proof membrane

Screed

Heater mat laid on concrete beddingand protected by screed

Concrete sub floor

U-values of cold store floor slab insulated with Polyfoam Floorboard Extra/Super

U-values (W/m2K)

Thickness Ratio of perimeter (m) to area (m2)

(mm) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

200 (75+75+50) 0.08 0.1 0.11 0.11 0.12 0.12 0.12 0.12

175 (100+75) 0.09 0.11 0.12 0.13 0.14 0.14 0.14 0.14

150 (75+75) 0.09 0.12 0.13 0.14 0.15 0.15 0.15 0.15

125 (75+50) 0.1 0.13 0.15 0.16 0.16 0.17 0.17 0.17

100 0.11 0.16 0.18 0.19 0.20 0.21 0.21 0.22

75 0.12 0.17 0.20 0.22 0.23 0.23 0.24 0.24


Insulation of cold store floorPolyfoam Floorboard insulation is laiddirectly over a damp proof membrane.The membrane is laid over a sub basecomprising concrete screed, heater matand concrete slab. The heater mat placedbelow the insulation prevents the subsoilfrom freezing. A reinforced concrete slab,either power floated or with otherspecified suitable finish would then overlaythe whole construction.

Installing the insulation in multiple layersreduces the stiffness of the insulation layer.This helps to reduce any voids formingbetween the insulation and the frost heaveprotection layer.

Polyfoam Floorboard Standard isrecommended for use in ice rinks.



Typical U-values for basement walls insulated with PolyfoamFloorboard Extra

Basement depth (m)Thickness (mm) 2.0 2.5 3.0 3.5

75 0.27 0.26 0.24 0.23

65 0.30 0.28 0.27 0.26

50 0.34 0.32 0.30 0.29Notes: The U-values have been derived from BS EN ISO 13370 and BCA/NHBC Approved Document Basement forDwellings. The calculations assume that the basement floor has a U-value of 0.25 W/m2K.

Insulation of basement wallsPolyfoam Floorboard Standard is placedagainst the tanking membrane. Forbasements between 2.5m and 5m deepPolyfoam Floorboard Extra is recommendedfor its greater compressive strength.

The Polyfoam Floorboards protect thetanking membrane as the excavation isbackfilled. A granular backfill orproprietary drainage membrane isrecommended to reduce water pressureon the waterproofing system.

Carefully backfill with free-draining granularmaterial to hold the drainage cavitymembrane and insulation in place.

The table shows the U-values for a typicalbasement wall insulated with PolyfoamFloorboard Standard.

The pattern of heat loss from a basementwall is complex, with the rate of heat lossdiminishing as the depth of the basementincreases. This is due to the insulationvalue of the ground behind the basementwall. A method for calculating U-values forbasements is given in BS EN ISO 13370and also in BCA/NHBC ApprovedDocument Basement for Dwellings.

Waterproofmembrane

PolyfoamFloorboard

Drainagechannelmembrane

Basement wall



Note: The above look up table assumes a simple rectangular floor plan and a fully detached building.

To calculate the actual P/A, take the internal measurements of the exposed floor perimeter only and calculate the total floor area.

Insert them into the formula below to find your P/A

P/A =Exposed perimeter of floorArea of floor

Length in metres3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

3 – – – 1.00 0.95 0.92 0.89 0.87 0.85 0.83 0.82 0.81 0.80 0.79 0.78 0.78 0.77 0.77 0.76 0.76 0.75 0.75 0.75

4 – 1.00 0.90 0.83 0.79 0.75 0.72 0.70 0.68 0.67 0.65 0.64 0.63 0.63 0.62 0.61 0.61 0.60 0.60 0.59 0.59 0.58 0.58

5 – 0.90 0.80 0.73 0.69 0.65 0.62 0.60 0.58 0.57 0.55 0.54 0.53 0.53 0.52 0.51 0.51 0.50 0.50 0.49 0.49 0.48 0.48

6 1.00 0.83 0.73 0.67 0.62 0.58 0.56 0.53 0.52 0.50 0.49 0.48 0.47 0.46 0.45 0.44 0.44 0.43 0.43 0.42 0.42 0.42 0.41

7 0.95 0.79 0.69 0.62 0.57 0.54 0.51 0.49 0.47 0.45 0.44 0.43 0.42 0.41 0.40 0.40 0.39 0.39 0.38 0.38 0.37 0.37 0.37

8 0.92 0.75 0.65 0.58 0.54 0.50 0.47 0.45 0.43 0.42 0.40 0.39 0.38 0.38 0.37 0.36 0.36 0.35 0.35 0.34 0.34 0.33 0.33

9 0.89 0.72 0.62 0.56 0.51 0.47 0.44 0.42 0.40 0.39 0.38 0.37 0.36 0.35 0.34 0.33 0.33 0.32 0.32 0.31 0.31 0.31 0.30

10 0.87 0.70 0.60 0.53 0.49 0.45 0.42 0.40 0.38 0.37 0.35 0.34 0.33 0.33 0.32 0.31 0.31 0.30 0.30 0.29 0.29 0.28 0.28

11 0.85 0.68 0.58 0.52 0.47 0.43 0.40 0.38 0.36 0.35 0.34 0.32 0.32 0.31 0.30 0.29 0.29 0.28 0.28 0.27 0.27 0.27 0.26

12 0.83 0.67 0.57 0.50 0.45 0.42 0.39 0.37 0.35 0.33 0.32 0.31 0.30 0.29 0.28 0.28 0.27 0.27 0.26 0.26 0.25 0.25 0.25

13 0.82 0.65 0.55 0.49 0.44 0.40 0.38 0.35 0.34 0.32 0.31 0.30 0.29 0.28 0.27 0.26 0.26 0.25 0.25 0.24 0.24 0.24 0.23

14 0.81 0.64 0.54 0.48 0.43 0.39 0.37 0.34 0.32 0.31 0.30 0.29 0.28 0.27 0.26 0.25 0.25 0.24 0.24 0.23 0.23 0.23 0.22

15 0.80 0.63 0.53 0.47 0.42 0.38 0.36 0.33 0.32 0.30 0.29 0.28 0.27 0.26 0.25 0.24 0.24 0.23 0.23 0.22 0.22 0.22 0.21

16 0.79 0.63 0.53 0.46 0.41 0.38 0.35 0.33 0.31 0.29 0.28 0.27 0.26 0.25 0.24 0.24 0.23 0.23 0.22 0.22 0.21 0.21 0.21

17 0.78 0.62 0.52 0.45 0.40 0.37 0.34 0.32 0.30 0.28 0.27 0.26 0.25 0.24 0.24 0.23 0.22 0.22 0.21 0.21 0.20 0.20 0.20

18 0.78 0.61 0.51 0.44 0.40 0.36 0.33 0.31 0.29 0.28 0.26 0.25 0.24 0.24 0.23 0.22 0.22 0.21 0.21 0.20 0.20 0.19 0.19

19 0.77 0.61 0.51 0.44 0.39 0.36 0.33 0.31 0.29 0.27 0.26 0.25 0.24 0.23 0.22 0.22 0.21 0.21 0.20 0.20 0.19 0.19 0.19

20 0.77 0.60 0.50 0.43 0.39 0.35 0.32 0.30 0.28 0.27 0.25 0.24 0.23 0.23 0.22 0.21 0.21 0.20 0.20 0.19 0.19 0.18 0.18

Wid

th in

met

res

What insulation thickness do you need to achieve a U-value of 0.25 W/m2K?

Step 1 Measure the internal length and width of your floor. Read off the value for P/A from the table below. (If your floor is not asimple shape, refer to the notes below right.)



Beam and block look up chart to achieve U-value of 0.25 W/m2K

Concrete slab look up chart to achieve U-value of 0.25 W/m2K

Step 2 Using the appropriate chart below, find your P/A in the left hand column.

Step 3 Read across the chart to the board with the appropriate floor loading to see what thicknessis required to achieve a U-value of 0.25.

Based on a ground thermal conductivity of 1.5 W/m2K

Based on a dense infill blocks between concrete beams



Knauf Insulation LtdPO BOX 10

Stafford Road

St Helens

MerseysideWA10 3NS

Ref: PD03003

Polyfoam Floorboard - SIG Insulation Floorboard.pdf · Polyfoam Floorboard is a high performance,...

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