GB2390619A - Sound-proofed floor - Google Patents

Abstract

In a floor comprising saddles 10c for receiving battens 20c which are surmounted by flooring 5c, soundproofing is provided by insertion of resilient sound proofing means 30c in the form of a layer formed from chips of open and closed cell foams bonded together in a random mix. Sound proofing may be inserted between two halves of a batten, underneath a batten and supported by a tray, above a batten as shown, under the saddle, or only within the saddle under the batten.

Description

IMPROVED BUILDING SYSTEM

FIELD OF INVENTION

The present invention relates to an improved building 5 system, and in particular, though not exclusively, to an improved flooring system. The present invention further relates to a method of constructing a floor, wall or ceiling. 10 BACKGROUND TO INVENTION

In traditional constructions it is common for concrete sub-floors to be uneven and outwith relevant tolerances.

There is thus generally a degree of stepping between adjacent units of the sub-floor and a measure of 15 longitudinal camber.

In situations in which it is required to lay upon an uneven substrate a floor arrangement having a level upper surface, it is known to provide flooring devices which extend heightwise within a gap formed between the substrate 20 and flooring panels or supports therefor, a height of each flooring device being selectable or adjustable according to the height of the gap at various appropriate locations.

Flooring panels are thus arranged to provide said required level surface and may comprise floor boards, 25 panels or such like which may be supported by timber

battens laid in a pattern across the floor area. It is, therefore, advantageous to provide a means for positioning the battens relative to the flooring devices which is compatible with the necessity to make adjustments to the 5 height of the flooring devices where appropriate to accommodate unevenness in the substrate.

Such prior arrangements are often referred to as timber based pedestal, cradle or saddle flooring systems.

GB 2 321 070A (DANSKIN) discloses a flooring component 10 comprising a saddle member adapted to be positioned upon a support means provided between a substrate and a flooring member(s)to be supported above the substrate, said saddle member comprising a plate member, said plate member being provided with flange means extending substantially 15 perpendicularly from marginal portions of a first surface of the plate member and adapted to engage said support means in use, and four L-shaped brackets extending outwardly of a second opposite surface of said plate member from positions extending inwardly of marginal portions of 20 the plate member, each L-shaped member having a right angled corner portion and being arranged so that said corners face each other in a spaced apart manner so as to define a cruciform channel therebetween.

GB 2 348 218A (DANSKIN) discloses a building system 25 providing at least one building component comprising a

saddle member and further providing at least one packing piece, the saddle member including a channel capable of receiving the at least one packing piece, wherein surfaces of the saddle member and packing piece which oppose one 5 another, in use, are provided with interengaging means such that, in use, the interengaging means co-operate so as to locate the packing piece at a predetermined position relative to the saddle member. Such a building system is particularly suitable as a flooring system.

10 The content of the aforementioned documents, also by the present Applicant, are incorporated herein by reference. It has been found that for some purposes known flooring systems have adequate acoustic absorbing 15 performance. However, for other purposes known flooring systems fall short of desired acoustic performance. There is, therefore, a need in the art to provide an improved flooring system which provides improved acoustic performance whilst still seeking to maintain ease of 20 levelling and installation, and also a sufficient level of resilience under load.

It is an object of at least one aspect of the present invention to obviate or at least mitigate one or more of the disadvantages in the prior art mentioned hereinbefore.

25 It is also an object of at least one aspect of the

l present invention to seek to address the aforementioned need in the art.

It is a further object of at least one embodiment of at least one aspect of the present invention to provide a 5 flooring system for quick and easy levelling of poor sub floors. It is yet a further object of at least one embodiment of at least one aspect of the present invention to provide a flooring system enabling a timber floating floor to be 10 installed economically directly over uneven concrete sub floors without a need for levelling screeds or awkward packing procedures. Such a system can be used as a support structure for ground floors and as an acoustic flooring system for party floors. Both can support Domestic and 15 Light Office loadings or greater, such as, Medium Office, sports floors, or the like.

It is a yet further object of at least one embodiment of at least one aspect of the present invention to provide a floating flooring system over a solid sub-floor such as a 20 concrete sub-floor, providing accommodation for services and offering resistance to transmission of impact and airborne sound.

It is a still further object of at least one embodiment of at least one aspect of the present invention 25 to provide a flooring system which provides levelling of

À 1 sub-floors while providing sufficient resilience to a floor and improved acoustic damping by providing a relatively soft layer at a suitable location, while preferably seeking to avoid point loading.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a building system having at least one saddle member adapted to be placed on or 10 against a building or supporting structure upon or against which the building system is to be provided; at least one batten capable of being received by the at least one saddle member; at least one substantially planar building member; and 15 wherein the building system further provides a resilient sound absorbing means intended in use, to be provided between the at least one substantially planar building member and the supporting structure.

20 Preferably, the resilient sound absorbing means is not fixedly provided within a batten receiving portion of the at least one saddle member.

In use, the/each at least one saddle member may be placed on or against the supporting structure, the/each at 25 least one batten may be received by the saddle member, and

I r the/each at least one batten may be fixed to at least one substantially planar building member, eg by nailing.

Preferably the resilient sound absorbing means comprises a resilient sound absorbing layer adapted to be 5 oriented substantially parallel with a supporting structure upon or against which the building system is to be provided. Provision of the resilient sound absorbing layer provides the building system with resilience under load and 10 enhanced sound attenuation as compared to a building system without such a sound absorbing layer.

In a most preferred form the building system is adapted for use as a flooring system, the at least one substantially planar building member comprising a flooring 15 member. In such a case the supporting structure may comprise a sub-floor such as a concrete sub-floor.

In one implementation the resilient sound absorbing means may comprise at least two distinct strata being adapted to provide resilience under load and enhanced sound 20 attenuation properties, respectively.

Advantageously, each strata has a differing distinct and discrete density.

Preferably at least one stratum should be of a great enough density to prevent a sound bridge being formed 25 between the timber batten and, eg a concrete sub-floor

r where the sub-floor is uneven.

Advantageously another stratum will be of a sufficiently low density to permit vertical deflection under load thereby allowing impact sound to be absorbed.

The two distinct strata may be formed from a resilient fibrous layer.

Preferably the fibrous layer is polyester fibre.

The/each fibrous layer may be attached to a lower surface of the/each batten.

10 Advantageously a fibrous layer may be attached to an upper surface of the/each batten.

The fibrous nature of the resilient layer may absorb airborne sound and reduce reverbation of airborne sound in the floor cavity.

15 Alternatively the two distinct strata may be formed from a cellular resiliently pliant polyether material of which the cells are open and from a cellular resiliently pliant polyethylene or polyurethane material of which the cells are closed, respectively.

20 A further alternative is that the two distinct strata be formed from reconstituted foam layer made of open and closed cell chips bonded together respectively, typically to form a layer approximately 20 to 25mm thick.

In a further most preferred implementation the 25 resilient sound absorbing means may comprise a single

r strata. The single strata may be formed from a cellular resiliently pliant polyether material of which the cells are open.

5 Alternatively, and most preferably, the single strata resilient sound absorbing means may comprise a reconstituted foam layer.

Preferably the reconstituted foam layer is formed from open and closed cell foams granulated into chips and bonded 10 together in a random mix.

Preferably the reconstituted foam layer has a density in the range 150 to 190 kg/m3, and preferably between 160 and 180 kg/m3.

Preferably the reconstituted foam layer has a 15 thickness of lOmm to 25mm and most preferably 20mm.

According to a second aspect of the present invention there is provided a building system having: at least one saddle member; at least one batten capable of being received by the 20 at least one saddle member; and at least one substantially planar building member; and wherein the at least one batten is provided with a resilient sound absorbing means.

25 In one embodiment the/each at least one batten may

comprise a first batten member and a second batten member, the resilient sound absorbing means being provided between the first and second batten members.

Preferably the resilient sound absorbing means is 5 fixed to the first and second batten members.

In another embodiment at least one surface of the batten is faced with the resilient sound absorbing means, said at least one surface being adapted to be disposed substantially parallel to a building or supporting 10 structure, in use.

For example, in the case of a flooring system the at least one surface of the batten may comprise an uppermost and/or a lowermost surface of the batten.

In the latter case, a supporting tray may be provided 15 along at least part of a length of the resilient sound absorbing means between the resilient sound absorbing means and a base of a batten receiving portion of the at least one saddle member.

Indeed the tray may be caused to extend between 20 adjacent saddle members.

The resilient sound absorbing means may comprise a single strata comprising a reconstituted foam layer.

The reconstituted foam layer may be formed from open and closed cell foams granulated into chips and bonded 25 together in a random mix.

The reconstituted foam may have a density in the range of 150 to 190 kg/m3, and preferably between 160 and 180 kg/m3. The reconstituted foam layer may have a thickness of 5 10 to 25 mm, and preferably around 20mm.

According to a third aspect of the present invention there is provided a batten comprising a first batten member and a second batten member, resilient sound absorbing means being provided between the first and second batten members.

10 According to a fourth aspect of the present invention there is provided use of a batten in a building system according to the second aspect, the batten being provided with a resilient sound absorbing means.

According to a fifth aspect of the present invention 15 there is provided a building system having: at least one saddle member adapted to be placed on or against a supporting structure upon or against which the building system is to be provided; at least one batten capable of being received by the 20 at least one saddle member; at least one substantially planar building member; and wherein the at least one saddle member is provided with a resilient sound absorbing means intended, in use, to be 25 provided between a base of a batten receiving portion of

the at least one saddle member and the supporting structure. The resilient sound absorbing means may comprise a single strata comprising a reconstituted foam layer.

5 The reconstituted foam layer may be formed from open and closed cell foams granulated luto chips and bonded together in a random mix.

The reconstituted foam may have a density in the range of 150 to 190 kg/m3, and preferably between 160 and 180 10 kg/m3. According to a sixth aspect of the present invention there is provided a saddle member adapted for use in the building system of the fifth aspect.

According to a seventh aspect of the present invention IS there is provided a building system having: at least one saddle member; at least one batten capable of being received by the at least one saddle member; and at least one substantially planar building member; and 20 wherein the building system further provides a resilient sound absorbing means capable of being placed, in use, between the batten and a base of a batten receiving portion of the at least one saddle member.

25 The resilient sound absorbing means may comprise a

substantially planar insert body adapted to be loosely held, ie removably received, within the batten receiving portion. The resilient sound absorbing means may comprise a 5 single strata comprising a reconstituted foam layer.

The reconstituted foam layer may be formed from open and closed cell foams granulated into chips and bonded together in a random mix.

The reconstituted foam may have a density in the range 10 of 150 to 190 kg/m3, and preferably between 160 and 180 kg/m3. According to an eighth aspect of the present invention there is provided a substantially planar insert body adapted for use in a building system according to the 15 seventh aspect of the present invention.

According to a ninth aspect of the present invention there is provided a building structure including a building system according to any of the first, second, fifth or seventh aspects of the present invention.

20 The building system may comprise at least part of an inter-party floor structure.

According to a tenth aspect of the present invention there is provided a floor, wall or ceiling construction including a building system according to any of the first, 25 second, fifth or seventh aspects of the present invention.

According to an eleventh aspect of the present invention there is provided a method of constructing a floor, wall or ceiling comprising the steps of: providing a building system according to the first, S second, fifth or seventh aspects including a plurality of saddle members; positioning the plurality of saddle members in a plurality of spaced rows over a surface of a building structure; 10 spacing saddle members within each of the rows and aligning the saddle members of each row so as to define a longitudinal batten path; inserting the batten(s) along the batten paths; securing the substantially planar building member(s) 15 to the batten(s) so as to form the floor, wall or ceiling.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the present invention will now be described by way of example only, and with reference to 20 the accompanying drawings, which are: Figure 1 a side view of a saddle member comprising part of a building system according to a first embodiment of the 25 present invention;

Figure 2 a top view of the saddle member of Figure 1; Figure 3 (a) to (d) various views of a packing piece (and modifications thereto) for use in the building system according to the first embodiment of the present invention; Figure 4 a cross-sectional view from above of a part of the building system according to the first embodiment of the present 10 invention providing the saddle member of Figure 1 and two packing pieces of Figures 3(a) to (d); Figure 5 a side view of the part of the building system of Figure 4; 15 Figure 6 an exploded perspective view of the part of the building system of Figure 4; Figure 7 an exploded perspective view of a part of a building system according to a 20 second embodiment of the present invention; Figure 8 an exploded perspective view of a part of a building system according to a third embodiment of the present 25 invention;

Figure 9 an exploded perspective view of a part of a building system according to a fourth embodiment of the present invention; 5 Figure 10 an exploded perspective view of a part of a building system according to a fifth embodiment of the present invention; and Figure 11 an exploded perspective view of a part 10 of a building system according to a sixth embodiment of the present invention. DETAILED DESCRIPTION OF DRAWINGS

15 Referring initially to Figures 1 to 6, there is provided a building system, generally designated 5a according to a first embodiment of the present invention, the building system 5a having: at least one saddle member 10a adapted to be placed on or against a building structure 20 15a upon or against which the building or supporting system 5a is to be provided; at least one batten 20a capable of being received by the at least one saddle member 10a; at least one substantially planar building member 25a; and wherein the building system Sa further provides a resilient 25 sound absorbing means 30a intended, in use, to be provided

between the at least one substantially planar building member 25a of the building structure 15a.

As can be seen from Figures 5 and 6, in use, each saddle member lea is placed on the supporting structure 5 15a, and a batten 20a is received by the saddle member lea, and each batten lea is fixed to a building member 25a, eg by nailing.

The resilient sound absorbing means 30a comprises a resilient sound absorbing layer 35a adapted to be oriented lo substantially parallel with the supporting structure 15a, upon which the building system 5a is provided.

The resilient sound absorbing layer 35a provides the building system 5a with resilience under load and enhanced sound attenuation as compared to a building system without 15 such a sound absorbing layer 35a.

The building system 5a is particularly suitable for use as a flooring system, the building member 25a comprising a flooring member 40a. In such case the supporting structure 15a likely comprises a sub-floor such 20 as a concrete sub-floor.

In one implementation the resilient sound absorbing means 30a comprises at least two distinct strata 45a;50a, adapted to provide resilience under load and enhanced sound attenuation properties respectively. Each strata 45a;50a 25 has a distinct and discrete density. At least one strata 45a; 50a is of a great enough density to prevent a sound

bridge being formed between the building member 25a and the concrete subfloor 15a where the sub-floor 15a is uneven.

The other strata 45a;50a will be of a sufficiently low density to provide a vertical deflection under load thereby 5 allowing impact sound to be absorbed in the layer 35a. In the present embodiment the two distinct strata 45a;50a are formed from a resilient fibrous layer, the fibrous layer being a polyester fibre. The fibrous nature of the resilient layer 35a absorbs airborne sound and reduces 10 reverberation of airborne sound in the floor cavity In a modification the two distinct strata 45a,50a are formed from a cellular resiliently pliant polyether material of which the cells are open and from a cellular resiliently pliant polyethylene or polyurethane material of which the 15 cells are closed, respectively.

In a further modification the two distinct strata 45a, 50a are formed from a reconstituted foam layer made of open and close cell chips bonded together, typically to form a layer approximately 20 to 25 mm thick.

20 In a yet further modification the resilient sound absorbing means 30a comprises single strata. The single strata can be suitably made from a cellular resiliently pliant polyether material of which the cells are open.

However in a most preferred modification the resilient 25 sound absorbing means 30a comprises a single stratum comprising a single reconstituted foam layer, the

reconstituted foam layer being formed from opened and closed cell foams granulated into chips and bonded together in a random mix. Such a reconstituted foam is commonly termed "chip foams". The reconstituted foam is selected to 5 have a density in the range of 150 to 190 kg/m3, and preferably between 160 and 180 kg/m3. Further, the reconstituted foam layer typically has a thickness of 10 to 25 mm, and preferably around lOmm.

The vibration and sound reducing properties of such 10 foams can be altered by varying the ratios of the mix and the densities of the finished foams. The open cell foam within the mixture absorbs high frequency vibrations. The closed cell foam in the mixture is aimed at reducing low frequency vibrations. Additionally, the closed cell chips 15 in the layer prevent the layer compressing completely under load, thereby negating the need for two distinct strata.

The acoustic performance of lightweight timber floating floors is poorest at lower frequencies up to 600Hz. It is preferable to select a density of 20 reconstituted foam, which has good sound absorption properties at these levels. Such a foam is manufactured by Recticel Ltd of Manton Road, Corby, Northants. At the frequencies of interest the 160 and 180 kg/m3 foams gave superior performance. Foams in this density range would be 25 preferred for use as the resilient layer in the saddle system.

Use of a reconstituted foam improves the acoustic performance in two ways. The open cell foam in the mixture absorbs airborne sound by dissipation with the foam. In addition, there is increased vertical deflection under 5 load, which enhances impact sound reduction.

As can be seen from Figures 5 and 6, in this first embodiment each batten 20a is provided with the resilient sound absorbing means 30a. The batten 20a comprises a first batten member 55a and a second batten member 60a, the 10 resilient sound absorbing means 30a being sandwiched between the first and second batten members 55a;60a. The sound absorbing means 30a and the batten members 55a and 60a can be held together, for example, by adhesive.

The saddle member lea comprises a plate member 65a 15 being provided with flange means 70a, adapted to engage a support means 75a, in use, and four L-shaped brackets 80a extending out of a second, opposite of said plate member 65a from positions extending inwardly of marginal portions of the plate member 65a, each L-shaped member 80a having a 20 right angled corner portion and being arranged so that said corners face each other in a spaced apart manner, so as to define a cruciform channel 85a therebetween. The brackets 80a which are, in this advantageous embodiment, moulded integrally with this plate member 65a may be of any 25 selected height, A, B. or C, depending upon the likely level of packing required, (as will be explained in later

detail hereinafter).

In use, the channel 85a will receive a through-batten 20 shown in broken lines in Figure 2 and in full lines in Figure 5, and where required will receive end portions of 5 one or two batten(s) 20a which will each abut a side surface of the through-batten 20a.

The flange means 70a are provided in order to engage with a portion of the support means 75a which may be in the form of a panel as shown in Figure 1, or alternatively one 10 or more stools, eg timber battens. A layer of resilient material may be provided on a lower surface of the panel to contact the supporting structure 15a beneath.

The supporting structure 15a or substrate is typically a floor of a building structure, and it may therefore be 15 necessary to vary the height of the assembly described above, so that an upper surface of the floor boards 40a will be substantially horizontally level. Packing pieces 90a are therefore provided to be placed in the channel 85a to a depth sufficient to compensate for the unevenness of 20 the substrate. As can be seen in Figure 5, where a through-batten 20a is to be supported, one or more substantially rectangular packing pieces 90a may be suitable. At least one recess or hole 95a on a contacting surface lOOa of the saddle member lOa is provided so as to 25 receive a nipple 105a extending from packing piece 90a, illustrated in Figures 3(a) to (c). The recess 45a and

nipple 105a co-operate to locate the packing piece 90a at a predetermined position relative to the saddle member 20a.

In this embodiment each nipple lOSa is cylindrical with a diameter suitable for engaging in cylindrical recess 95a.

5 Furthermore, the packing piece 90a also has at least one recess 96a designed to engage a further nipple 105a extending from a second packing piece 90a (not shown).

In this way a number of packing pieces 90a may be placed in combination within the saddle member 20a to 10 achieve levelling of uneven sub-floors. As no gluing of packing pieces 90a is normally required site installation is faster than alternative systems. Packing is generally permissible up to 5mm below top of shoulders of the saddle member 2Oa.

15 As can be seen from Figure 2, in this embodiment the batten 20a beneficially runs perpendicular to the packing pieces 22a. However, it will be appreciated that the batten 20a may in some instances be run parallel to the packing pieces 22a.

20 The packing piece 90a, as illustrated in Figure 3(b), may have a chamferred edge llOa to facilitate ease of offering of the packing piece 90a between the batten 20a and saddle member lea or other packing piece 90a, and thereby assist in placing the packing pieces 90a in the 25 required positions. Alternatively, the edge of the packing piece 90a may be wedged shaped as depicted in Figure 3(d).

In a preferred form of the present embodiment a number of the packing pieces 90a may be of different thicknesses to one another. Thus the plurality of packing pieces 90 may comprise a set of packing pieces comprising a plurality 5 of subsets, each subset comprising at least one packing piece, the packing piece of each subset being of the same colour, packing pieces of different subsets being of different colours. Such colour coded packing pieces are disclosed in previous GB 2 34 218A also by the present 10 Applicant, the content of which is incorporated herein by reference. The battens 20a may be softwood support bearers and are placed within the saddle lea to support the flooring members 40a, and can be preservative treated if required.

15 They are normally supplied in 1800 mm lengths for ease of handling and the standard bearer heights are 22mm, 36mm and 52 mm.

The saddle plate member or cap 65a may be 137 x 97mm in size or any other suitable size and may be manufactured 20 from tough injection moulded plastic with different shoulder heights A, B. C to accommodate standard batten sizes. The design of the saddle plate 65a means that it can also support cross noggins at access panels and perimeter bearers. The saddle plate 65a may be glued on 25 top of the resilient saddle support 75a.

The packing pieces 90a may be rigid, conveniently

dimensioned to be a snug but loose fit within the channel 85a, and may also be manufactured from tough injection moulded plastic.

The saddle supports 75a may be variously manufactured 5 from WBP plywood, oriented strand board (OSB) or softwood, depending on the required floor height. All may have 9mm thick resilient acoustic foam adhered to the underside to assist impact sound resistance. A likely resilient saddle support 75 height is 15mm inclusive of foam.

10 Referring now to Figure 7, there is shown a building system, generally designated 5b, according to a second embodiment of the present invention. The second embodiment is similar in many respects to the building system 5a of the first embodiment, like parts being identified by like 15numerals but suffixed 'b'. However, in the second embodiment a surface of the batten 20b is faced with the resilient sound absorbing means Bob, said surface being adapted to be disposed substantially parallel to the building structure 15b, in use. In the case of a flooring 20 system the surface of the batten 20b in this embodiment comprises a lowermost surface of the batten 20b. In order to seek to obviate point loading a supporting tray 115b is provided along at least part of a length of a resilient sound absorbing means Job, between the resilient sound 25 absorbing means 30b and a base of a batten receiving portion of the saddle member 20b, ie channel 85b. In a

preferred form the tray 115b extends between adjacent saddle members 2Ob.

Referring now to Figure 8, there is shown a third embodiment of a building system, generally designated 5c, 5 according to a third embodiment of the present invention.

The building system 5c of the third embodiment is substantially similar to that of the building system 5a of the first embodiment, like parts being identified by like numerals but suffixed 'c'. However, in the building system 10 5c, the sound absorbing means 30c comprises a layer on the surface of the batten 20c. In the case of a flooring system the surface of the batten 20c comprises in this embodiment an uppermost surface of the batten 20c. This embodiment is in some situations advantageous over the 15 second embodiment since this third embodiment does not inherently suffer from the problem of point loading, and does therefore not require provision of an additional supporting tray.

Referring now to Figure 9, there is shown a building 20 system, generally designated Ed, according to a fourth embodiment of the present invention. The building system 5d is substantially similar to the building system 5a of the first embodiment, like parts being designated by like numerals but suffixed 'd'. However in the fourth 25 embodiment, the resilient sound absorbing means 30d is provided on a surface of the batten 20d. In the case of

the flooring system the surface of the batten 20c comprises a lowermost surface of the batten 20c as can be seen from Figure 9. In this embodiment no tray is provided as was provided in the second embodiment since the problem of 5 point loading may be acceptable in certain scenarios.

Referring now to Figure 10, there is shown a building system, generally designated be, according to a fifth embodiment of the present invention. The building system Be is substantially similar to the building system 5a of TO the first embodiment, like parts being designated by like numerals, but suffixed 'e'. However, in this embodiment the saddle member 20e is provided with the resilient sound absorbing means 3Oe, intended in use, to be provided between a base of a batten receiving portion of the saddle 15 member 20e, (ie channel 85e) and the supporting structure 15e. In this embodiment the resilient sound absorbing means 30e comprises a resilient fibrous layer comprising at least two strata and adapted to provide resilience under load, thus providing enhanced sound attenuation properties.

20 Referring finally to Figure 11, there is shown a building system, generally designated 5f, according to a sixth embodiment of the present invention. The building system 5f is similar to the building system Of of the first embodiment, like parts being designated by like numerals 25 but suffixed 'f'. However, in the building system 5f the resilient sound absorbing means 30f comprise a

i substantially planar insert body 35f adapted to be placed and loosely held within a batten receiving portion, ie cruciform channel 85e of the saddle member 20e so as to be releasably or removably insertable therein. In this 5 embodiment the resilient sound absorbing insert body 35f is substantially cruciform in shape and is made from a resilient fibrous material comprising at least two distinct strata adapted to provide resilience under load, thus providing enhanced sound attenuation properties.

10 In a modification the body 35f may be fixed or adhered to at least one packing piece 90f, and advantageously an uppermost surface thereof.

In each of the disclosed embodiments the building system 5a to 5f in use as a floor system comprises timber 15 floor boards or lengths of suitable chipboard or plywood 40a to 40f fixed to timber battens 20a to 20f. The battens 20a to 20f are of any suitable length, but are generally determined by the length dimensions of the supporting structure. The battens 20a to 20f have a substantially 20 square or rectangular cross sectional area and can be made from any suitable material such as softwood timber but may also include sheet material such as plywood, oriented strand board (OSB), chipboard, hardboard, medium density fibreboard (MDF), and the like.

25 The floor boards 40a - 40f are attached to the upper horizontal surface of the timber batten 20a - 20f by any

suitable fixing means such as nails, screws or adhesive.

In cases where the resilient sound absorbing means 30a - 30f comprises a fibrous material layer which comprises a resilient layer manufactured from substantially 100% 5 polyester fibre, the fibres are processed and layered into a web of a given weight. This weight is typically 1000 1500 grams/m2. The web is then felted to create a layer comprising two strata of discrete densities. The web is then thermally bonded. Although in this particular example 10 there are only two strata this is only for the purposes of illustration and should not be regarded as limiting on the scope of invention as there can be more than two strata included in the adapted fibrous layer.

The upper stratum 45a is typically 5 - 15 mm but 15 preferably 5 - 12 mm thick with a typical density of in the range of 65 - 150 kg/m3, but preferably 85 kg/m3. The lower stratum 50a is typically 8 - 25 mm (but can be as low as 7mm) thick with a typical density in the range of 25 kg/m3, but preferably 45 kg/m3. The top stratum 45a has to 20 be of a high enough density to prevent a sound bridge being formed between the building member 25a to 25f and a concrete sub-floor 15a - 15f, especially where the sub floor 15a - 15f is uneven. The more dense fibre protects the less dense fibre from damage and provides a better 25 surface for adhesion to the timber battens or flooring panels. On the other hand the lower strata 50a has to be

of a low enough density to permit vertical deflection under load which hereby allows impact sound to be absorbed in the fibrous layer. These two distinct strata 45a,50a in the fibrous layer prevent complete compaction of the layer and S over a period of time act as a resilient cushioning layer against impact from above preventing impact sound being transmitted through the floor construction. The less dense stratum 45a,50a compresses under loading from above and the fibrous nature of the resilient layer absorbs airborne 10 sound, preventing it from reverberating in the floor cavity. The less dense stratum 45a, 50a then recovers position when the load is removed.

The overall thickness of the fibrous layer can vary but is generally in the range of between 13 - 40 mm but 15 preferably 17 - 25 mm (but it can be as low as 12mm or as high as 27mm or thereabouts). The thickness and density of the strata 45a;50a can be varied in the manufacturing process as required, depending on the type of floor construction in which it is to be used.

20 Polyester fibre is beneficial in that it will absorb only a small amount of water causing little effect to the product. Furthermore, the polyester fibre is physiologically inert. Further, it does not cause skin irritations and breathing difficulties in the workers who 25 are laying the floor system.

It will be appreciated that the embodiments of the

invention hereinbefore described are given by way of example only, and are note meant to limit the scope thereof in any way. Further, it will be appreciated that various modifications may be made within the scope of the invention 5 and that the invention may be employed particularly in the forming of floors but also walls and/or ceilings.

It will be appreciated that in further embodiments the resilient sound absorbing means of the disclosed embodiments may be utilized in combination with one another 10 to further improve an acoustic performance.

Further the resilient sound absorbing means may be adhered to the bottom, eg by gluing, or may be loosely laid in relation to the bottom.

Claims (43)

1. A building system having: at least one saddle member adapted to be placed on or against a supporting structure upon or against which the 5 building system is to be provided; at least one batten capable of being received by the at least one saddle member; and at least one substantially planar building member; wherein 10 the building system further provides a resilient sound absorbing means intended, in use, to be provided between the at least one substantially planar building member and the supporting structure, and the resilient sound absorbing means comprises a layer formed from chips of open and 15 closed cell foams bonded together in a random mix.

2. A building system as claim in claim 1, wherein the resilient sound absorbing means is not fixedly provided within a batten receiving portion of the at least one 20 saddle member.

3. A building system as claim in either of claims 1 or 2, wherein, in use, the/each at least one saddle member is placed on or against the supporting structure, the/each at 25 least one batten is received by the saddle member, and the/each at least one batten is fixed to at least one

substantially planar building member.

4. A building system as claimed in any preceding claim, wherein the resilient sound absorbing means comprises a 5 resilient sound absorbing layer adapted to be oriented substantially parallel with a supporting structure upon or against which the building system is to be provided.

5. A building system as claimed in any preceding claim, 10 wherein the building system is adapted for use as a flooring system, the at least one substantially planar building member comprising a flooring member.

6. A building system as claimed in any of claims 1 to 5, 15 wherein the resilient sound absorbing means comprise a single strata.

7. A building system as claimed in any of claims 1 to 6, wherein the resilient sound absorbing means comprises a 20 reconstituted foam layer.

8. A building system as claimed in claim 7, wherein the reconstituted foam layer has a density in the range 150 to 190 kg/m3.

9. A building system as claimed in claim 8, wherein the

reconstituted foam layer has a density in the range 160 to 180 kg/m3.

10. A building system as claimed in any of claims 7 to 9, wherein the reconstituted foam layer has a thickness of lOmm to 25mm.

11. A building system as claimed in claim 10, wherein the reconstituted foam layer has a thickness of around 20mm.

12. A building system having: at least one saddle member; at least one batten capable of being received by the at least one saddle member; and 15 at least one substantially planar building member; wherein the at least one batten is provided with a resilient sound absorbing means comprising a layer of reconstituted foam.

13. A building system as claimed in claim 12, wherein the/each at least one batten comprises a first batten member and a second batten member, the resilient sound absorbing means being provided between the first and second 25 batten members.

14. A building system as claimed in claim 13, wherein the resilient sound absorbing means is fixed to the first and second batten members.

S

15. A building system as claimed in claim 12, wherein at least one surface of the at least one batten is faced with the resilient sound absorbing means, said at least one surface being adapted to be disposed substantially parallel to a supporting structure, in use.

16. A building system as claimed in claim 15, wherein in the case where the building system comprises of a flooring system the at least one surface of the batten comprises an uppermost and/or a lowermost surface of the batten.

17. A building system as claimed in claim 16, wherein where the at least one surface of the at least one batten comprises a lowermost surface, a supporting tray is provided along the least part of a length of the resilient 20 sound absorbing means between the resilient sound absorbing means and a base of a batten receiving portion of the at least on saddle member.

18. A building system as claimed in claim 17, wherein the 25 tray extends between adjacent saddle members.

.

19. A building system as claimed in any of claims 12 to 18, wherein the resilient sound absorbing means a comprises a single strata.

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20. A building system as claimed in any of claims 12 to 19, wherein the reconstituted foam layer is formed from open and closed cell foams granulated into chips and bonded together in a random mix.

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21. A building system as claimed in any of claims 12 to 20 or 31, wherein the reconstituted foam layer has a density in the range of 150 to 190 kg/m3.

22. A building system as claimed in claim 21, wherein the 15 reconstituted foam layer has a density between 160 and 180 kg/m3.

23. A building system as claimed in any of claims 12 to 22, wherein the reconstituted foam layer has a thickness of 20 lOmm to 25mm.

24. A building system as claimed in claim 23, wherein the reconstituted foam layer has a thickness of around 20mm.

25 25. Use of a batten in a building system according to any of claims 12 to 24, wherein the batten is provided with a

resilient sound absorbing means comprising a layer of reconstituted foam.

26. A building system having: 5 at least one saddle member; at least one batten capable of being received by the at least one saddle member; and at least one substantially planar building member; wherein 10 the at least one saddle member is provided with a resilient sound absorbing means intended, in use, to be provided between a base of a batten receiving portion of the at least one saddle member and a supporting structure, the resilient sound absorbing means comprising a layer of 15 reconstituted foam.

27. A building system as claimed in claim 26, wherein the resilient sound absorbing means comprises a single strata.

20

28. A building system as claimed in either of claims 26 or 27, wherein the reconstituted foam layer is formed from chips of open and closed cell foams bonded together in a random mix.

25

29. A building system as claimed in any of claims 26 to 28, wherein the reconstituted foam layer has a density in

t the range of 150kg/m3 to 190 kg/m3.

30. a building system as claimed in claim 29, wherein the reconstituted foam layer has a density in the range of 5 lOOkg/m3 to 180 kg/m3.

31. A saddle member adapted for use in the building system of any of claims 26 to 30.

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32. A building system having: at least one saddle member; at least one batten capable of being received by the at least one saddle member; and at least one substantially planar building member; 15 wherein the building system further provides a resilient sound absorbing means capable of being placed, in use, between the batten and a base of a batten receiving portion of the at least one saddle member, the resilient sound absorbing 20 means comprising a layer of reconstituted foam.

33. A building system as claimed in claim 32, wherein the resilient sound absorbing means comprise a substantially planar insert body adapted to be loosely and removably held 25 within a batten receiving portion of the at least one saddle member.

34. A substantially planar insert body adapted for use in a building system according to either of claims 32 or 33.

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35. a building system as claimed in any of claims 1 to 11, claims 12 to 24, claims 24 to 30, or claims 32 to 33, wherein the building system comprises a flooring system.

36. A building structure including a building system 10 according to any of claims 1 to 11, claims 12 to 24, claims 26 to 30, or claims 32 to 33.

37. A building structure as claimed in claim 36, wherein the building system comprises at least part of an inter 15 party floor structure.

38. A floor, wall or ceiling construction including a building system according to any of claims 1 to 11, claims 12 to 24, claims 26 to 30 or claims 32 or 33.

39. A method of constructing a floor, wall or ceiling comprising the steps of: providing a building system according to any of claims 1 to 11, claims 12 to 24, claims 26 to 30 or claims 32 or 25 33, including a plurality of saddle members; positioning the plurality of saddle members in a

plurality of spaced rows over a surface of a support structure; spacing saddle members within each of the rows and aligning the saddle members of each row so as to define a 5 longitudinal batten path; inserting the batten(s) along the batten paths; securing the substantially planar building member(s) to the batten(s) so as to form the floor, wall or ceiling.

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40. A building system as hereinbefore described with reference to the accompanying drawings.

41. Use of a batten as hereinbefore described with reference to the accompanying drawings.

42. A substantially planar insert body as hereinbefore described with reference to the accompanying drawings.

43. A method of constructing a floor, wall or ceiling as 20 hereinbefore described with reference to the accompanying drawings.