Plycem High Performance Non-Combustible Subfloor Panels

Plycem uses Portland cement as the primary binder with cellulose fiber reinforcement, creating a cementitious matrix similar to traditional concrete. USG Structo-Crete is gypsum-based (calcium sulfate dihydrate) with perlite aggregate for lightness and fire resistance.

Key Differences:

• Moisture resistance: Portland cement (Plycem) is more resistant to prolonged moisture exposure than gypsum
• Alkalinity: Plycem has higher pH, providing better resistance to mold/mildew in humid conditions
• Dimensional stability: Both perform similarly, but cement-based products typically exhibit lower expansion/contraction
• Environmental durability: Portland cement maintains properties better in freeze-thaw cycling

Both materials are non-combustible and achieve comparable fire ratings in UL-tested assemblies. Selection often comes down to project-specific factors like budget, lead time, and environmental exposure conditions.

While Plycem is manufactured for exterior cladding applications in other product lines, the High Performance Subfloor variant is engineered specifically for interior structural floor applications. For temporarily weather-exposed scenarios (e.g., multi-story construction before roof/wall enclosure), the panels can withstand incidental moisture exposure during normal construction timelines.

Best Practices for Weather Exposure:

• Cover panels with tarps during extended rain events
• Ensure adequate drainage to prevent standing water
• Allow panels to dry thoroughly before installing finished flooring
• Inspect for dimensional changes if panels have been repeatedly wetted

For permanent exterior floor applications (e.g., balconies, decks), consult technical support for appropriate Plycem exterior-grade products.

Plycem panels are compatible with all standard flooring systems:

• Ceramic Tile / Porcelain: Install per TCNA (Tile Council of North America) guidelines using modified thin-set mortar. Apply waterproofing membrane for wet areas (bathrooms, kitchens).
• Luxury Vinyl Tile/Plank (LVT/LVP): Requires smooth, level surface. Fill joints with patching compound and sand smooth. Follow manufacturer's adhesive recommendations.
• Engineered/Solid Hardwood: Can be nailed, glued, or floated depending on product specifications. Moisture barrier recommended.
• Carpet: Direct glue-down or tackless strip installation. Use appropriate padding.
• Resilient Sheet Flooring: Apply self-leveling underlayment over joints for seamless surface.
• Epoxy/Polished Concrete Coatings: Clean surface thoroughly, apply bonding primer, install coating system per manufacturer specs.

Surface Preparation Notes: For ultra-smooth floor finish requirements (e.g., sheet vinyl, high-gloss epoxy), consider applying self-leveling cement-based underlayment to create Class 5 flatness per ACI 117.

Plycem panels have been used successfully in high seismic zones (Seismic Design Categories D, E, F) throughout Central and South America. The panels' inherent flexibility and fiber reinforcement provide good seismic performance when properly installed.

Seismic Design Considerations:

• Fastener Schedule: Maintain proper fastener spacing and edge distances - do not omit fasteners to "save time"
• Diaphragm Design: Work with structural engineer to verify diaphragm shear capacity meets code requirements
• Blocking: Provide adequate blocking at panel edges perpendicular to joists for load transfer
• Connection Details: Ensure proper nailing/bolting of framing connections per engineered plans

For projects in SDC D-F, coordinate with the project structural engineer to verify that the floor assembly meets the required diaphragm strength and stiffness. Plycem can provide load-tested diaphragm values upon request for engineering calculations.

Sound transmission performance depends on the complete floor/ceiling assembly, not just the subfloor panel. Tested Plycem assemblies have achieved:

• STC (Sound Transmission Class): 50-55 in typical assemblies with gypsum board ceiling and batt insulation
• IIC (Impact Insulation Class): 50-55 when used with appropriate underlayment (e.g., cork, rubber, foam)

Improving Acoustic Performance:

• Add 5/8" Type X gypsum board on resilient channels below joists: +5-8 STC points
• Install acoustic underlayment (rubber/cork) before finished flooring: +10-15 IIC points
• Use fiberglass batt insulation in joist cavities: +3-5 STC points
• Increase floor mass by using 25mm or 30mm panels: +2-4 STC points

For projects requiring specific STC/IIC targets (e.g., multifamily building codes requiring STC 50/IIC 50), request tested assembly details from technical support.

CSI MasterFormat Section: 06 16 00 - Sheathing (Wood, Plastics, and Composites) or 09 29 00 - Gypsum Board

Sample Specification Language:

3-Part Spec Template Available: Contact technical support for complete Section 06 16 00 specification in CSI format including products, execution, and quality assurance requirements.

Yes, Plycem panels are compatible with both hydronic (water-based) and electric radiant floor heating systems. The cementitious composition provides excellent thermal conductivity compared to wood-based subflooring.

Installation Considerations:

• Hydronic Systems: Install tubing or heating cables per manufacturer's specifications. Use thin-set mortar or self-leveling compound to embed heating elements and create thermal mass.
• Electric Mat Systems: Apply directly over Plycem panels, following mat manufacturer's adhesive and temperature guidelines.
• Thermal Expansion: Maintain proper expansion joints per radiant system design. Plycem's low shrinkage characteristics minimize movement concerns.
• Temperature Limits: Maximum continuous surface temperature should not exceed 85°F (29°C) to prevent damage to floor finishes.

For detailed radiant heating integration guidelines, consult both the Plycem Installation Guide and the radiant system manufacturer's technical documentation.

Plycem panels contain Portland cement and silica-based materials. Cutting operations generate respirable dust containing crystalline silica, which requires proper safety measures:

OSHA Crystalline Silica Standard (29 CFR 1926.1153) Compliance:

• Respiratory Protection: Use NIOSH-approved N95 respirator minimum for dry cutting. P100 preferred for heavy cutting operations.
• Dust Control: Use tools with integrated dust collection or HEPA vacuum attachment to minimize airborne dust.
• Ventilation: Perform cutting operations in well-ventilated areas or outdoors when possible.
• Wet Cutting: Consider wet-cutting methods to eliminate dust generation (requires appropriate saw and water supply).

Handling Precautions:

• Wear work gloves - fresh-cut edges can be sharp
• Use proper lifting techniques - panels weigh 150-225 lbs (2-person lift recommended)
• Wear safety glasses during cutting and installation
• Wash hands and exposed skin after handling to remove cement/silica dust

Installed panels pose no health concerns. The product does not contain asbestos, formaldehyde, or volatile organic compounds (VOCs).

Current Availability (as of October 2025):

• 20mm panels: 1,500+ units in stock at Long Beach, CA warehouse (immediate availability)
• 22mm, 25mm, 30mm panels: Available by container order from factory (6-8 week lead time)

Container Load Specifications:

• 40' High Cube container: ~300 panels (20mm), ~270 panels (22mm), ~240 panels (25mm)
• Shipping from Costa Rica/El Salvador to US West Coast: 14-21 days ocean transit
• Customs clearance: 2-5 business days
• Delivery to job site: 1-3 days from Long Beach warehouse

Project Planning Recommendations:

• For projects requiring >1,000 panels: Place order 10-12 weeks before installation date
• For projects requiring <500 panels: Current stock typically sufficient for 3-5 business day delivery
• Large projects (1,000+ panels): Contact sales for dedicated production slot and delivery schedule coordination

Contact Robertson Carrillo Z. at +1 (415) 933-5738 or robert@plycemca.com for project-specific lead time confirmation and delivery coordination.