Installation method of SPD water-based foamed polyurea sound insulation board

SPD water-based foamed polyurea sound insulation and insulation board is a new floor sound insulation and insulation material with all-water foamed polyurea foam as the core material and reinforced with composite fiberglass mortar cloth. It is mainly used for sound insulation and thermal insulation of residential floors, and is suitable for scenes such as rough houses and fine decoration floor heating. The installation process takes into account the continuity of sound insulation performance and the overall sealing of the insulation layer. The following is a complete process explained one by one.

1. Preparation before construction

Basic inspection and treatment. The floor base must be thoroughly inspected before installation. The surface of the concrete floor slab should be smooth, dry, clean, and free of floating dust, oil stains, release agent residues, and loose objects. The flatness deviation of the base layer should be controlled within ±3 mm. If the deviation is too large, it must be leveled with cement mortar first. Cracks, holes, and protrusions on the floor should be repaired in advance, especially around the pipes passing through the floor, which should be filled and smoothed with fine stone concrete to ensure that there are no defects in the base layer that may cause the insulation board to be elevated or broken.

Material acceptance and storage. Check whether the specifications and models of the incoming plates are consistent with the design. The common specifications are 600 mm × 1200 mm, and the thickness is available in 15 mm, 20 mm, 25 mm, etc. Check whether the surface of the board is damaged, deformed, or damp, and whether the fiberglass mortar cloth surface layer is complete. The boards should be stacked flatly in a dry and ventilated room. They should not be exposed to the sun or rain to prevent moisture from affecting the sound insulation performance of the foamed polyurea core material.

Preparation of tools and auxiliary materials. It is necessary to prepare special water-based adhesive (or supporting mortar), rubber hammer or wooden mallet, utility knife or electric saw, 2-meter ruler, ink line, tape measure, rubber scraper, waterproof tape (width not less than 80 mm), special sealant, etc.

2. Line elasticity and typesetting

Lay out the layout according to the actual size of the room. Control lines pop up around the floor to determine the laying direction of the panels. Generally, the staggered seam paving method is used. The longitudinal joints of adjacent boards should be staggered by no less than half of the board length, and the local minimum staggered seam should not be less than 100 mm to avoid the reduction of sound insulation performance caused by through seams. Lay horizontally and vertically, and the width of the joints between boards should be controlled within 1 mm. The tighter the joints, the better the sound insulation effect.

3. Plate cutting

Use a utility knife or electric saw to cut according to the elastic wire size. When cutting, advance at a constant speed along the edge of the plate to ensure that the cut edge is straight and burr-free. It is recommended to use an electric saw for multi-layer boards (when the thickness is large), and the depth of the score must be reached at one time. After cutting is completed, use sandpaper to smooth the cut edges to remove debris and avoid gaps caused by uneven edges during installation.

4. Paste installation (core link)

The pasting of SPD water-based foamed polyurea sound insulation and insulation boards is a key process that determines the sound insulation and insulation effect. It is recommended to use the full-glue method for construction.

Apply adhesive. Coat the special water-based adhesive evenly on the back of the board, and the compacted thickness of the adhesive layer is about 3 mm. The full bonding method is to evenly cover the entire back of the board with the adhesive, ensuring that the bonding area is no less than 90% of the total area of ​​the board. This can ensure to the greatest extent that there is no cavity between the board and the base layer. Cavities are a taboo for sound insulation. The strip bonding method can also be used according to the site conditions - use a toothed trowel to evenly apply adhesive stripes with a strip width of 10 mm, a thickness of 10 mm, and a center distance of 50 mm on the back of the board in the horizontal direction. However, the sound insulation continuity of the strip bonding method is not as good as that of the full bonding method. It is recommended to give priority to full bonding.

Put stickers on the wall. Paste the adhesive-coated board to the floor quickly to prevent the adhesive from forming a skin on the surface and losing its stickiness. When pasting, gently tap with a rubber hammer or wooden mallet to ensure that the board and the base layer are completely attached. At the same time, use a 2-meter ruler to check the flatness at any time. The plates must be tightly packed together without leaving any gaps. Gaps caused by uneven cutting should be filled with adhesive and smoothed, and there should be no visible gaps.

Yin and Yang angle and tube root treatment. The boards at the yin and yang corners should be laid as a whole to avoid joints at the corners. Around the pipes that penetrate the floor slab, the gap between the slab and the pipes should be filled and smoothed with adhesive first, and then sealed with sealant to ensure that the continuity of the sound insulation layer is not destroyed.

5. Seam and interface sealing

The treatment of board seams is directly related to the sound insulation performance. Waterproof tape with a width of not less than 80 mm should be pasted on the joints of the panels, and the width of the tape on both sides of the joints should be approximately equal. When pasting, use a scraper to smooth it from the middle to both sides to squeeze out the air bubbles in the tape and smooth out wrinkles to ensure that the tape is completely tight with the edge of the board. If any unsealed seams are found, cover them with a layer of waterproof tape on the outside to strengthen the seal. All vertical joints between the panels and the wall are also sealed with waterproof tape, and no through-going gaps are allowed, because sound waves will penetrate through the smallest gaps.

6. Installation of fixing parts (depending on design requirements)

If the design requires the use of mechanical fixing, the installation of the fixings should be completed within 8 hours and within 24 hours after the panels are pasted. Use a percussion drill to drill holes at the designed location, with a hole diameter of about 10 mm, a depth of about 60 mm into the base layer, and a depth of anchoring the fixings into the base layer of not less than 50 mm. Each board is provided with a fixing piece. The self-tapping screws should be tightened so that the nail head is flush with the board surface or slightly lower. Make sure that the tail is back-tightened to fully anchor it to the base layer. The purpose of the fasteners is to prevent the panels from slipping while the adhesive cures, while also enhancing long-term stability.

7. Surface layer construction (adaptation of protective layer and floor heating)

After the SPD water-based foamed polyurea sound insulation board is installed and accepted, a concrete protective layer or floor heating layer needs to be constructed above it.

Laying steel mesh. The protective layer should be equipped with a two-way welded steel mesh (such as Φ3 mm @ 50 mm or Φ 4 mm @ 100 mm). The mesh should be placed in the middle of the protective layer, about 15 to 20 mm from the top surface. The overlap width of the mesh should not be less than 80 mm. When laying, place a 50 mm × 50 mm, 20 mm thick pad under the mesh to ensure that the mesh is in the center of the protective layer. Pay attention to avoid the wire tip from piercing the insulation board and waterproof tape when tying.

Pour fine stone concrete protective layer. The slump of concrete should be strictly controlled within 150 mm. It is advisable to use a 30-kg roller to roll back and forth until slurry emerges from the surface. The low-lying areas should be filled with concrete. Wait 2 to 3 hours for the concrete to slightly absorb water and then calender it with an iron trowel. The trolley transporting concrete during pouring should be pushed on the laid wooden boards and should not be pushed directly on the steel mesh or insulation board to avoid crushing the sound insulation layer. When pouring at the corners of walls and pipes passing through floor slabs, concrete must not be poured into the sealed gap between the slab and the wall.

Floor heating adapts to the scene. If it is a refined floor heating project, low-temperature radiant hot water pipes should be laid above or below the steel mesh according to the design requirements, and the thickness of the protective layer and reinforcement should be adjusted accordingly. The construction should comply with the relevant specifications for low-temperature radiant hot water pipe heating floors.

8. Maintenance and finished product protection

After the protective layer is laminated, it should be covered in time and sprinkled with water for curing. The curing time should be no less than 7 days. During the curing period, it is strictly prohibited to push trolleys, stack heavy objects or step on it at will. If a hardcover floor heating scenario is used, the first heating of the floor heating should be carried out slowly to avoid the expansion of water vapor inside the board caused by a sudden rise in temperature.

9. Key points for quality acceptance

After the installation is completed, you should focus on checking the following items: whether the panel joints are tight and seamless, whether the waterproof tape is intact and not falling off, whether the flatness of the panels is up to standard, whether the fixings are secure, and whether the protective layer is intact without cracking. The sound insulation performance can be tested on site after completion through professional instruments to ensure that it meets the floor sound insulation requirements of the newly implemented "Residential Project Code" in 2025.