Replacing weetabix sodden chipbrd floor in kitchen

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Hi folks,

A couple of months ago when pulling up the horrid floor covering in our kitchen I noticed that the floor was somewhat "bouncy" around and under a unit. When the floor covering was pulled up and the unit removed, it appears that some bad plumbling has been leaking down the wall and creeping under the floor, turning an entire section of the floor into a mushy wet weetabix like substance - which crumbled to bits in my hands. Under the crumbling section of chipboard I found a polystyrene insulation block covered by a blue plastic membrane sheet. Under this is what appears to be a floor consisting of solid concrete blocks.

I'm left with a bit of a dilema, as the kitchen floor itself is a bit of a mess. It's largely uneven with different thicknesses of chipboard, bumps, humps and slopes, gaps and warped sections. Should I simply replace the knackered section and be left with a functional but largely unsatisfactory job, or should I rip the whole lot up and start from scratch? (gulp).

Some questions that might help me make up my mind.

1) While I appreciate nobody here is psychic lol, what am I likely to find? Will there likely be a framework, or is it possible that the chipboard could just "float" on the polystyrene blocks? There doesn't appear to be any framework around the edges where the knackered section has been pulled up.

2) If I remove the whole lot, will any insulation need to go down first, or could I simply level the concrete floor a little (with a self levelling compound) and put down something like a 18mm plywood? Would this need to be on a framework or could it be layed directly on top of the concrete?

3) if the floors coming up, I'm thinking it might be an idea to partition a section of kitchen off, as we'd like a walk in closet. I'm guessing it would be best to partition this before laying the plywood?

My apologies if this all sounds a bit mad. To give you some background, I'm competant at basic DIY and woodworking, but haven't a clue about the insulation/damproofing side of things. I'm confident I can get the woodworking side of things spot on, but don't want to do anything crazy that will result in a cold or damp kitchen.

Oh and the kitchen is 5m x 4m :-)

Cheers
 
chipboard is complete rubbish

hack it all up and replace with 18mm WBP ply

if the expanded polystyrene is damaged, you can buy it in slabs 2440x1220 and cut to fit

the floor floats on top of the foam. Glue the T&G to hold the boards together.

internal partitions are usually put up after the floor is down.

while you have it up, take the opportunity to remove any underfloor rubble, clear airbricks, repair any damage, possibly add insulation, do any underfloor plumbing or wiring that you may want.

here's one I did earlier

View media item 4494
 
Hi John, thanks for that (and sorry for the late reply).

Right, the floor appears to consist of the following (haven't taken it all up yet - just a bit more in the rotten corner)

1) Concrete/Slabs on the base - some very bumpy bits
2) Polystyrene Blocks
3) Damp Proof Membrane plastic sheet
4) Chipboard

There's no joists or anything.

It's been suggested (sounds like a good idea to me) that I install some joists which would help to bridge the bumpy bits (assuming they're not too large and/or aren't just rubble that can be shovelled away).

I'm guessing the polystyrene could be cut and placed in between the joists.

Am I right in assuming that the DMP should go on BEFORE the joists go down, or am I getting this horribly wrong? I'm okay with the whole woodworking aspect - but the insultation/damp proofing side is completely alien to me.

Cheers
 
if it is on concrete, you wouldn't normally install joists (they will go rotten as there is no ventilation, and the floor will get damp). I am assuming it is a ground floor.

the method of construction you have got is OK, you can get expanded polystyrene slabs if yours are damaged, and lay flooring ply over the top, if your concrete is damaged you can bash off high spots and fill hollows with mortar. You do not nail the ply down, it is called a floating floor. I am not experienced in this method but someone will probably be along in a minute.
 

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