Field-assembled flooring systems with isolation boards
View Patent ↗Described herein are methods for installing field-assembled flooring systems that include isolation boards on a wall frame, a subfloor, or on both the wall frame and the subfloor. The underlayment can be a hybrid design that includes a combination of isolation panels and cementitious product. The flooring systems are 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 isolation 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. The isolation boards can be installed on walls rather than or in addition to the isolation boards installed on the subfloor.
1. A method for installing a flooring system, the method comprising:
securing a back face of wall isolation boards to studs of a wall frame so that a bottom edge of the wall isolation board is adjacent to a subfloor and a top edge of the wall isolation board is less than or equal to about 12 inches above the subfloor, the wall isolation boards being installed adjacent to one another to cover a portion of the wall frame, the wall isolation boards comprising cellulose fiberboards;
installing a sound control membrane over a portion of the subfloor;
installing an isolation strip to a front face of the wall isolation boards with a bottom edge of the isolation strip adjacent to the sound control membrane; and
pouring cementitious product over the sound control membrane so that the poured cementitious product reaches a targeted height that does not exceed a top edge of the isolation strip.
2. The method of claim 1 wherein securing the wall isolation boards to the wall frame includes using at least two dry wall screws for each wall isolation board.
3. The method of claim 1 further comprising applying a tape material at a transition between the sound control membrane and the isolation strip.
4. The method of claim 1 wherein the sound control membrane extends over the entire subfloor between wall frames of a building.
5. The method of claim 1 wherein the wall isolation boards comprise fire-rated cellulose fiberboard.
6. The method of claim 1 wherein a thickness of the wall isolation boards is greater than or equal to about 0.5 inches and less than or equal to about 1 inch.
7. The method of claim 1 wherein the cementitious product comprises gypsum concrete.
8. The method of claim 1 wherein the targeted height is less than or equal to about 1.5 inches.
9. The method of claim 1 wherein an edge of the sound control membrane is adjacent to the wall isolation boards.
10. A method for installing a flooring system, the method comprising:
securing a back face of wall isolation boards to studs of a wall frame so that a bottom edge of the wall isolation board is adjacent to a subfloor and a top edge of the wall isolation board is less than or equal to about 12 inches above the subfloor, the wall isolation boards being installed adjacent to one another to cover a portion of the wall frame, the wall isolation boards comprising cellulose fiberboards;
securing floor isolation boards to a first area of the subfloor, wherein the floor isolation boards are adjacent to a front face of the wall isolation boards, the floor isolation boards comprising cellulose fiberboards;
installing a sound control membrane over a portion of a second area of the subfloor; and
pouring cementitious product over the second area of the subfloor so that the poured cementitious product reaches a targeted height that does not exceed a top edge of the floor isolation boards.
11. The method of claim 10 wherein securing the wall isolation boards to the wall frame includes using at least two dry wall screws for each wall isolation board.
12. The method of claim 10 wherein securing the floor isolation boards to the subfloor includes using a combination of adhesives and mechanical fasteners.
13. The method of claim 10 further comprising applying a tape material at a transition between the sound control membrane and the floor isolation boards.
14. The method of claim 10 wherein the sound control membrane extends over the entire second area of the subfloor.
15. The method of claim 10 wherein the wall isolation boards comprise fire-rated cellulose fiberboard.
16. The method of claim 10 wherein the floor isolation boards comprise fire-rated cellulose fiberboard.
17. The method of claim 10 wherein a thickness of the wall isolation boards is greater than or equal to about 0.5 inches and less than or equal to about 1 inch.
18. The method of claim 10 wherein a thickness of the floor isolation boards is greater than or equal to about 1 inch and less than or equal to about 2 inches.
19. The method of claim 10 wherein the cementitious product comprises gypsum concrete.
20. The method of claim 10 further comprising installing drywall above the wall isolation boards.