Field-assembled wall and flooring systems
View Patent ↗Described herein are methods for installing field-assembled flooring systems wherein the underlayment is a hybrid design that includes a combination of structural board and cementitious product. The hybrid design is configured to reduce or eliminate the curing time requirement after pouring the cementitious product (e.g., gypsum concrete). The field-assembled flooring systems can reduce or eliminate the chances of the onset of mold due to high moisture levels by removing the cementitious product from the prone areas and replacing it with structural boards. The structural boards (e.g., cellulose fiberboards) can be installed in non-critical areas such as underneath cabinets, around the perimeter of the floor, under bathtubs, in non-walk-in closets, anywhere drywall reaches the floor, or the like.
1. A flooring system for a dwelling that is formed at least in part by a plurality of interior walls, the flooring system including:
a plurality of isolation boards secured to a subfloor in a targeted area adjacent to the plurality of interior walls of the dwelling to define one or more open portions of the subfloor between the plurality of interior walls;
a plurality of structural boards secured on top of the plurality of isolation boards; and
a cementitious product poured in the one or more open portions of the subfloor so that the poured cementitious product contacts one or more of the plurality of isolation boards and the plurality of structural boards but does not contact any of the plurality of interior walls,
wherein the plurality of isolation boards and the plurality of structural boards define a pour stop for the cementitious product.
2. The flooring system of claim 1 wherein the one or more open portions includes a portion of a kitchen.
3. The flooring system of claim 1 wherein the one or more open portions includes a portion of a bathroom.
4. The flooring system of claim 1 wherein the one or more open portions includes a portion of a bedroom.
5. The flooring system of claim 1 further comprising a second plurality of isolation boards secured to the subfloor in a second targeted area separated from each of the plurality of interior walls.
6. The flooring system of claim 5 wherein the second plurality of isolation boards further provides the pour stop for the cementitious product.
7. The flooring system of claim 6 wherein the second plurality of isolation boards is configured to be positioned beneath a kitchen island.
8. The flooring system of claim 6 wherein the second plurality of isolation boards is configured to be positioned beneath a bathtub.
9. A method for installing a hybrid underlayment of a flooring system in a dwelling that is formed at least in part by a plurality of interior walls, the method comprising:
securing a plurality of isolation boards to a subfloor in a targeted area adjacent to the plurality of interior walls of the dwelling to define one or more open portions of the subfloor between the plurality of interior walls;
securing a plurality of structural boards on top of the plurality of isolation boards; and
pouring cementitious product in the one or more open portions of the subfloor so that the poured cementitious product contacts one or more of the plurality of isolation boards and the plurality of structural boards but does not contact any of the plurality of interior walls,
wherein the plurality of isolation boards and the plurality of structural boards define a pour stop for the cementitious product.
10. The method of claim 9 wherein the one or more open portions includes a portion of a kitchen.
11. The method of claim 9 wherein the one or more open portions includes a portion of a bathroom.
12. The method of claim 9 wherein the one or more open portions includes a portion of a bedroom.
13. The method of claim 9 further comprising securing a second plurality of isolation boards to the subfloor in a second targeted area separated from each of the plurality of interior walls.
14. The method of claim 13 wherein the second plurality of isolation boards further provides the pour stop for the cementitious product.
15. The method of claim 14 wherein the second plurality of isolation boards are configured to be positioned beneath a kitchen island.
16. The method of claim 14 wherein the second plurality of isolation boards are configured to be positioned beneath a bathtub.