Rubber flooring systems made from 100% recycled tyres

by Tania Wannenburg
Van Dyck Jnl 1 16

It is interesting to note that Van Dyck is amongst the most active and progressive companies addressing these issues.

Recycling of waste tyres for use in secondary products is relatively new in South Africa and therefore not many companies have adapted to it. With the world’s focus on environmental issues, it is interesting to note that Van Dyck is amongst the most active and progressive companies addressing these issues. This is one of the reasons that led Van Dyck to begin the manufacturing of acoustic underlays, cradles and sound barriers using rubber crumb.

In 2014 a joint venture was formed between the Mathe Group and PFE International Inc. PFE is the holding company that owns Van Dyck. The Mathe Group began manufacturing small quantities of rubber granulate from used truck tyres in late 2011. The recycling procedure consists of a three-phase crushing process and packaging of the resulting rubber crumb. During the process, magnets remove metal components and separators produce different sized particles or rubber crumbs for different applications. Thereafter, the rubber crumb is transported to Van Dyck for the manufacturing of pure rubber acoustic underlays branded as Eco-lay and InstaLay (a ‘peel & stick’ version of Ecolay). These underlays are used under-floor coverings to minimise noise between different levels in apartment and office blocks. Ever since 2012, Van Dyck has been prioritising the emphasis on developing unique, differentiated and sustainable products for their customers’ diverse preferences.

InstaCradle is one of the latest innovations by Van Dyck. This product made from 100% recycled rubber tyres is specially designed for raised flooring and high-performance acoustic and sports flooring and also acts as a unique floor-levelling system. This ‘Cradle to Cradle’ and long-lasting rubber crumb is fully recyclable with a guarantee of 60 years. Together with cradle packers, timber battens overlaid with chipboard, plywood or a hardwood, the cradles and base packers form the prime component in creating high-performance acoustic and sports floors which can accommodate a variety of floorcoverings.

Widely used in refurbishment, conversions and new-build projects, these versatile and environmentally friendly acoustic cradles are able to provide an extensive range of finished floor heights. These include raised floors to accommodate under-floor services and acoustic floors offering extremely high standards of acoustic performance. They also provide accurate and rapid onsite levelling to eliminate any unevenness in the structural floor surface. The Cradle and Batten System is designed either as a raised floor, accommodating underfloor services, or as a floor offering extremely high standards of acoustic and sports performance.

Van Dyck manufactures all the rubber components such as the cradles (25mm or 40mm high), base packers (10mm or 30mm high) and cradle packers (2mm or 5mm high) in their factory in Durban, and has a list of recommended suppliers that can assist with the battens and chipboard or plywood. The system is suitable for new-build and refurbishment projects for both domestic and commercial applications and both for indoor and outdoor use.

Benefits of recycled-rubber-crumb cradles
•    Rubber-crumb cradles have a 60-year guarantee
•    Fast, easy and cost-effective to install
•    Cradles are loose laid and do not require fixing to subfloor
•    Adjustable to produce varying finished floor heights
•    Onsite levelling to overcome uneven floors
•    No levelling screeds or drying times needed
•    Manufactured using recycled rubber to provide long-lasting, high-performance solutions
•    Fully recyclable, genuine ‘cradle-to-cradle’ product
•    Excellent acoustic performance
•    System can provide a void for services/underfloor heating
•    Cradles are unaffected by water
•    Cradles can be used in areas of abnormal loadings
•    Require no maintenance
•    Available as cradle and packer components or as a full system
•    Can accept a range of floor finishes including ceramic tiles
•    Hardwood floors can be secret-nailed directly to timber battens
•    Structural loadings minimised due to lightweight system
•    Suitable for use with outside decking

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