NEW ERA UNOBAT SPORTS FLOOR
NEW ERA UNOBAT SPORTS FLOOR
|D 1.0||General information|
|D 1.2||Batten System Information|
|D 10.2||Specifier's Information|
|D 10.2.1||Laying Instructions|
BEFORE LAYING THE FLOOR
The building must be weather tight. The heating system must be installed and tested, and during the heating season there should be a constant heat supply.
Cast concrete elements, including casting of sockets for fixtures and fittings, screeding and other wet trades which can contribute moisture to the building, e.g. priming of paintwork, must also be completed.
The relative humidity in the building must be between 35 - 65% RH (UK) and the temperature approx. 16-20°C.
The residual moisture contained in the concrete or screed must not exceed 90% RH. (UK 75% acc. To BS 8201).
For timber subfloors the moisture content should not exceed 12%.
Solid floor boards should always be laid immediately after delivery.
The packing on the bundles must not be removed until just prior to laying the floor, i.e. no acclimatising of the boards on site must take place.
NB: Read these instructions carefully before laying begins. In case of doubt please contact your Junckers distributor before installing the floor.
1. MOISTURE BARRIER
A moisture barrier of min. 0.20 mm PE membrane must be laid on all concrete subfloors.
The moisture barrier is laid with an overlap of 200 mm at all joints, continuing up walls etc.
The membrane must be taped with waterproof tape at all joints.
2. LAYING OF SUBSTRUCTURE - C/C 411 MM
The battens and cradles are laid parallel to the shortest side of the room to ensure that the boards are laid parallel to the longest side of the room.
The first row of cradles is placed at 100 mm from the wall to the centre of the cradle. The second row is laid at 341 mm to the first row. All other rows are spaced at 411mm apart from the last row which is again spaced at 100 mm centre from the wall.
At the end of each batten row the end of the cradle should be placed 30mm from the wall. Batten ends within the floor must finish in the centre of a cradle. The exception is the first and last cradle of every row where the batten end is at the end of the cradle.
The second row of battens spaced at 341mm centres is based on an expansion gap of 30mm being left at the perimeter, which is the requirement for a 33 x 18m sports hall.
For smaller or larger floors please consult Junckers Ltd. for advice.
3. BATTEN JOISTS MUST NOT BE IN LINE
Batten end joints must not be in line but must be staggered as much as possible.
Cradle centres along the batten:
- 22 x 45 mm batten: 300 mm
- 36 x 45 mm batten: 450 mm
- 48 x 45 mm batten: 600 mm
- 63 x 45 mm batten: 700 mm
The entire substructure must be placed with an expansion gap of minimum 30 mm from all walls, net posts, pipes, etc.
4. START ROWS
The first 3 rows of cradles should be set out at the correct spacing and then laser levelled into place using packing pieces which are placed into the top of the cradles.
Battens can then be placed in cradles.
The maximum permitted amount of packing per cradle is 15 mm before the next size cradle is required. (Max. 12 mm thick packing when the S Zero cradles are used)
Please note if using the wooden packing pieces, these must be glued to the cradle, to one another and then glued to the underside of the batten.
The polypropylene packing pieces do not require gluing as they lock into place, except for the top packer which must be glued to the batten.
5. BATTEN CENTRES, REMAINING BATTENS
Remaining batten rows across the floor are spaced at 411 mm.
Regular levelled Datum rows should now be set out maintaining the 411 mm batten centres.
The distance of the datum rows will be dependant on the length of the straight edge used to span.
With the datum rows now in place the floor areas are effectively divided into bays and the floor is ready for the positioning and levelling of the remaining cradles to fill the bays.
NB. The last row of cradles are spaced 100 mm from the wall to the centre of the cradle.
It is recommended that the foam pads are removed from cradles positioned in doorways and beneath fixed stationary objects to avoid deflection in these areas. This recommendation will also apply where floor heating grills have to be accommodated.
6. SUPPORT BATTENS
Place extra support battens (New Era UnoBat) at post-sockets, pipes etc.
The distance to walls net posts and pipes should be a minimum 30 mm.
If the floor is used as a squash court, permanent spacing blocks at 500 mm centres must be fitted into cradles and fixed as packing blocks between the first row of battens and the front row of the court.
7. LAYING OF FLOOR BOARDS
If the floor is more than 12 m wide laying must begin in the middle of the sports hall.
The two centre boards are joined with a loose tongue which is glued to both boards down the full length of the hall.
The floor boards are secret nailed, see part 10.
8. REMEMBER THE 10-BOARD RULE
In order to allow the floorboards to undergo expansion due to natural humidity changes in the building, the boards must be laid according to the 10-board rule which indicates the width of 10 floor boards when laid. Compliance must be checked periodically during the installation process.
The 10-board rule is chosen on the basis of the maximum expected relative humidity of the building during the year. eg. an expected relative humidity of max 65% RH normally gives a 10-board measurement of approx 1294 mm.
The 10-board measurement is achieved by placing plastic spacers between every row of floor boards during installation. Spacers are available from your Junckers distributor.
If in doubt please contact Junckers Technical Department.
9. SUPPORT OF HEADER JOISTS & FLOOR PATTERN
All board header joints must be fully supported by battens and all boards must be laid in the pattern shown in the drawing.
NB: with a batten distance 411.1 mm, the distance between board header joints in two consecutive rows must be 2 x 411.1 mm = 822.2 mm, as shown in the drawing.
To avoid creaking, the boards are pushed down on the battens while they are nailed.
Use Junckers machine J-nails, 2.2 x 45 mm or 50 mm Porta nails with pneumatic nail gun. The boards are secret nailed at an angle of 45°.
Do not nail closer than 50 mm to stave joints and never in the board end joints.
NB: The first and last rows of boards installed must be face nailed or screwed and then covered with matching filler.
11. DISTANCE TO WALLS & BUSHINGS
The distance between the floorboards and walls/vertical fixed installations is calculated as 1.5 mm per running metre of floor width on each side, and at end walls 1 mm per running metre of floor length, with an overall distance of minimum 15 mm.
Bushings must be fitted so that both vertical and horizontal movement of the floor is unimpeded. The size of the internal opening of the bushing must exceed that of the post by minimum 40 mm. At the outermost edges of the floor all bushings are mounted
eccentrically towards the centre of the floor in relation to the post-sockets in the concrete, so that the floor can expand freely.
Place extra support battens at net poles, pipes, etc
12. SPORTS HALL SKIRTING
The foot of the skirting must lie flat and be in contact with the floor. End joints may be either butt jointed together or 45º mitre the joints between sections to enhance the visual effect of the joint.
The skirting can be either glue fixed to the walls or screw fixed with cups and screws.
Do not fix the skirting to the Junckers floor and ensure that the skirting is not exerting any downward pressure on the floor.