SAPboard Helps Contractors, Owners and Architects Save Time, Save Money and Build a Better Project

In the past, cementitious underlayments had been the solution to many subflooring challenges. Unfortunately, this solution came with its own set of problems and challenges. For many years, these problems became an accepted part of the construction process. RSP Industries founders Rick Raymond and Rob Edmonds knew that there had to be a better solution.

Rick’s 35 years of experience in manufacturing, gave him a keen understanding of the possibilities from a manufacturing perspective. While Rob’s 30 years in the Development and Construction Industry gave him valuable insights into the problems and concerns that architects, owners and contractors face every day in the field. Together, they envisioned a strong, user-friendly solution that would eliminate the need for gypcrete, solve the most common subflooring challenges and help provide significant cost and schedule savings.

After years of research and development, they achieved all of those objectives with an innovative new product. RSP Industries introduced SAPboard, the first viable alternative to cementitious underlayments. This high-quality, easy-to-install, subflooring product saves time, reduces cost and helps prevent some of the most common problems that are encountered in many construction projects.

The Challenges of Cementitious Underlayments

Subfloor installation is often a time-consuming process, which can bring construction to a halt and require trades to be demobilized while cementitious underlayments dry and cure. This is because cementitious underlayments contain large amounts of moisture, which require continuous ventilation and often a heat source to rapidly remove this moisture from the structure. But “rapid” is a relative term because this process can often take a full week or more.

This prolonged drying process is necessary because, if the moisture is not properly removed, the contractor risks mold development at the construction site, which can require remediation and delay the schedule even further – adding significant cost to the project. To avoid this type of costly delay, the general contractor may need to supply mechanical ventilation and an adequate heat source to speed the drying time. This also adds costly, heavy equipment to the project.

Even with the proper ventilation and heating equipment, the average drying time for a standard cementitious underlayment is lengthy and the process itself requires additional prep time, pouring time, curing time, and sealing time. This is all before you can even get to the subflooring process. This standard subfloor installation process not only introduces significant amounts of standing moisture to your structure – which increases the risk of mold, it also adds costly time to your construction schedule. These are all things that can negatively impact your bottom line.

According to one source,

North American commercial property owners spend an estimated $2.4 billion on remediation of structures and floor coverings as a result of moisture-related flooring failures annually. An additional $1.2 billion is spent on topical moisture treatments (of varying effectiveness) in an effort to address moisture issues prior to the floor covering being installed. These incidents add significant cost to any project in terms of project delays, unplanned expenses associated with costly topical systems, flooring replacement, and litigation, as well as the incalculable lost opportunity cost associated with business disruptions, loss of reputation, and loss of return customers.1
This all translates into risk and potential lost revenue for contractors and owners alike.

SAPboard Is the Simple Solution to Many Common Subfloor Challenges

No Increased Risk of Mold in the Structure

Unlike the standard subflooring process, SAPboard provides a strong, integrated, eco-friendly, sound dampening, UL 528 certified subfloor solution that eliminates many of these costly risks and delays. SAPboard doesn’t add unnecessary moisture into your otherwise dry construction environment because SAPboard requires NO cementitious underlayments. NO added moisture reduces the risk of mold development. It also means that NO additional prep, pouring, drying, and curing time is required when using SAPboard. SAPboard gives you a streamlined, significantly reduced construction schedule and reduces the risk of budget overruns caused by mold issues.

Quick, Easy Installation

The SAPboard installation process is quick and simple. SAPboard is installed in the same manner as a traditional subfloor, but without the usual prep time and hassle of a traditional subfloor and cementitious underlayment. To install, just ensure framing and truss are square and level after all permanent bracing is installed. Space SAPboard on staggered centers, applying SAPboard adhesive to top of truss. Ensure space is equal on all four sides and that the SAPboard tongue fully engages in the groove as indicated. Drill any necessary plumbing and electrical holes as floors are built. And remove any high points as you would with any floor prep. SAPboard makes subfloor installation just THAT easy. No dry and cure time. No demobilizing trades.

Schedule and Cost Savings

For contractors, SAPboard offers significant savings resulting from schedule improvements. And for owners, SAPboard helps to optimize the project completion timeline, resulting in earlier revenue opportunity. In fact, a 110-day construction schedule using cementitious underlayments can be cut to just 87 days by simply choosing SAPboard. On a typical 4 story, 80,000 sq. ft. multifamily building, that’s a 23 day schedule savings - and even more on larger projects. That’s 3 weeks less construction time for the average contractor and it’s three weeks sooner that the owner can begin to realize revenue. These savings and cash flow benefits help ensure that your project stays on time and on budget.

Sound Absorption That is Built Into the Subfloor

Sound Absorption Panel Boards are the latest innovation in acoustic subfloor design. Large structures such as multifamily dwellings and hotel buildings are especially prone to sound transmission between floors. From the constant hum of electronic equipment in large office buildings to the everyday sounds of life in multi-family structures, the close proximity of units both above and below demands that attention is given to undesired sound transmission. SAPboard solves many of the sound transmission challenges that architects and builders face in multifamily structures by incorporating sound abatement right into the subfloor.

The innovative design of SAPboard provides a high-quality sound barrier that is easily incorporated directly into the structure as the building is framed, allowing for continuity of installation without the need to demobilize trades in order to pour gypcrete. SAPboard combines the ease of installation of a traditional subfloor with the sound damping qualities of the best acoustic isolation solutions in the industry, preventing noise transfer between living spaces and eliminating the many potential problems associated with cementitious underlayments that would normally be required with a traditional subfloor.

Certifications

RSP tested more than 200 material combinations to identify a sound absorption solution that exceeds minimum requirements of the International Building Code. The result of this testing is SAPboard, a product that achieves sound absorption rates as high as 58 IIC and 62 STC.

In addition to its sound dampening abilities, SAPboard has literally proved itself under fire. SAPboard withstood temperatures exceeding 1,600 degrees and passed the 1-hour fire rating test with flying colors. This performance has earned SAPboard its UL 528 certification.

Eco-Friendly Design with a Near Zero Carbon Footprint

SAPboard is also outstanding with regard to sustainability. Manufactured with yellow pine from renewable sources and recycled rubber, SAPboard has a near zero carbon footprint. And the water-based adhesive system is resistant to moisture, creating a strong, stable product that is free from solvents and other harmful emissions. This is in stark contrast to cementitious underlayments, which emit CO2. In fact, a recent study showed that,

Cement is responsible for 7% of global man-made greenhouse emissions, making it the world's second largest industrial source of carbon dioxide, according to the International Energy Agency. Data from the United States Geological Survey -- the scientific agency of the US government -- reveals that global cement production was responsible for about 4 billion pounds of CO2 emissions in 2017 alone.2
The elimination of cementitious underlayments in construction would significantly decrease this huge carbon footprint.

Exceptional Quality and Durability

In addition to all of the obvious benefits and advantages, SAPboard features a robust design with exceptional strength and stiffness, giving you both the highest quality and exceptional performance. In the field, SAPboard allows for easy machining and adhesion, resulting in a completely hassle-free installation. SAPboard also offers exceptional dimensional stability, which resists warping, twisting and bowing. You won’t find a tougher subfloor than SAPboard. But when it comes to quality and strength, seeing is believing. If you’d like to see the difference for yourself, you can see it in a series of videos where SAPboard is put to the test.

In the Load Deflection Test, SAPboard easily handled 500 lbs., demonstrating its superior stability. In the test, SAPboard easily withstands more than twice the weight that a typical OSB can handle. In the Drop Test, SAPboard deflected a cinder block that was dropped from 25’, demonstrating this product’s exceptional strength and durability. In the Impact Test, a side-by-side demonstration shows how SAPboard deflects a 2x4 that is propelled into it at 36ft/sec, while the same 2x4 easily pierces through a standard OSB. And, just for fun, you can watch as SAPboard handily defeats a commodity OSB in Kettle Bell Challenge game of cornhole.

Put simply, SAPboard is the new gold standard of subfloors. In every aspect, for architects, for contractors, and for owners, SAPboard provides superior installation and performance benefits. SAPboard is available in 2x8 and 4x8 sheets, but custom sizes can also be produced on request.

Choose SAPboard to ensure that your project stays on time, on budget and surpassing expectations.