Installation of the seamless Acoustic Boards system
DEKOZELL
®
ROBUST
- rendered with DEKOZELL
®
Acoustic Finish
supersmooth
Step
Picture / Proceeding
Instruction
1
Prepare Substrate similar as required to lay
standard ceramic tiles. Required load-
beraring capacity of substrate is 15kg/m².
Installation of the DEKOZELL
®
ROBUST Acoustic
Panels is quite similar to laying standard ceramic
tiles. Standard tile adhesive mortars can be used
to adhere the DEKOZELL
®
ROBUST Acoustic
Panels. Area density of the Panels is 15kg/m².
In General:
The substrate must be firm, dry, clean, and load-
bearing, as well as free from
sinter layers, efflorescence and release agents.
New base coats must set and harden for at least
14 days.
Check existing coatings for their load-bearing
capacity. Remove any non load-bearing
or structurally weak coatings.
2
If required, level out surface irregularities.
Be sure that the surface is smooth. Most tile
cements mortars can be used as hole fillers, too.
Refer to the technical datasheet of the specific ti
le
adhesive that will be used.
3
Apply tile adhesive to the ROBUST panels.
Keep gable side and edges of panels clean.
Do not use dot-bead-method!
Important:
Apply tile adhesive to the side of the
ROBUST panels with the chamfered edges
!
Use a notched trowel to apply tile adhesive. Be
sure to keep the gable sides of the panel (edges)
clean from adhesive.
For easier, faster and safer application we
recommend to mask 15-20mm painters tape along
the edges before tile adhesive is applied, then
remove the tape.
It is recommended for correct and safe installation
,
to apply adhesive mortar to panel backside all-
over, not only dot-bead method:
to prevent thermal bridging and water
steam condensing
to assure complete impact resistance (esp.
walls an ceilings flying ball proof)
to prevent acoustic blocking of panel
surface by oozed out mortar
4
Insert Picture:
Apply Acoustic Finish to
gable sides.
Prior to installation of next panel
DEKOZELL
®
Acoustic Finish is applied to
the gable edges of the already installed
panels.
DEKOZELL
®
Acoustic Finish is only applied in a
relatively thin layer at the end of the process. Dr
y
film thickness is approx. 40% less then wet film
thickness. Therefore all joints of the acoustic
panels need to be sealed properly prior to the
application of the finial coat finish. Easiest and
most efficient way to seal this joint is right duri
ng
the installation process of the panels. If the next
panel is edged to the prior one the finish will squ
id
out. Leave the bead like it is and let it dry – it
will
be automatically removed during the sanding
process later on.
The DEKOZELL
®
Acoustic Finish is sound
transparent and very easy to sand when dry. Since
the drying time of the finish is much more than 8
hours, it is the perfect choice to use this product
as
a sealant for the panel joints.
Important:
Do not
use tile adhesive to seal the panel joints.
Large parts of the acoustic panels would lose the
capability to absorb sound since the tile adhesive
is not sound transparent!
5
Stick the acoustic panel on to the wall or ceiling
and slide it into its final position.
Do not
use excessive force or even a
hammer!
Make sure no adhesive mortar pollutes the
surface of the acoustic panels. Only the
DEKOZELL
®
Acoustic Finish is sound
transparent and therefore later on no
barrier for sound waves to enter the
acoustic panel.
Do not glue panel joint with adhesive
mortar to prevent acoustic blocking of
panel surface by oozed out mortar. Instead
use DEKOZELL
®
Acoustic Finish to “glue”
panel joint together. Leave the squid out
bead of Finish like it is and let it dry – it will
be automatically removed during sanding
process later on.
6
Acoustic Panels can be easily cut into size
using standard wood cutting equipment.
Using standard wood cutting equipment the
Acoustic Panels can be easily cut into size. A so
called “Japanese saw” is doing excellent work for
clean, precise and nearly dust free cuts. Jigsaw,
holesaw and cutter knife are also very suitable
tools. Also on a circular saw very efficient cuts c
an
be performed directly on side.
Socket Outlet boxes can be glued into the acoustic
panels using adhesive mortar.
6
Use disk sander and sanding paper grit
size P40 to smooth complete wall or ceiling.
Use disk sander to remove the beads of squid out
DEKOZELL
®
Acoustic Finish. Sand complete wall
or ceiling to smooth out any misalignment of the
acoustic panels.
Use disk sander only in combination with vacuum
cleaner to prevent sanding dust entering the pores
of the acoustic panels.
Use only sanding paper grit size P40
. Coarse
sanding dust is less likely to block the acoustic
pores of the acoustic panels then fine sanding
particle would do.
7
Vacuum of the complete surface. Vacuum
accurately since this step is mission critical
.
Vacuum of the complete wall or ceiling very
accurately to remove any sanding dust from the
pores of the acoustic panel.
Important:
This is the step which is really mission critical
for
the success of proper noise absorption capability
of the DEKOZELL
®
ROBUST Acoustic system later
on. DEKOZELL
®
Acoustic Finish is sound
transparent, however sanding dust blocking the
pores is not. If sanding dust is not removed
accurately prior to application of the rendered
acoustic finish, then only a limited noise absorpti
on
performance will be accomplished.
8
Spray on DEKOZELL
®
Acoustic Finish to
the acoustic panels with fine spray pattern.
Use Hopper Gun or fine plaster spraying
machine to apply DEKOZELL
®
Finish
refer to workinstruction “Mix up and colour
in DEKOZELL
®
Acoustic Finish“
refer to workinstruction “Application of
DEKOZELL
®
Acoustic Finisch with Hopper
Gun or fine plaster spraying machine
Inomat M8“
Spray DEKOZELL
®
Acoustic Finish in round
overlapping circles on to surface of the acoustic
panels. Adjust spraying equipment to a fine spray
pattern. Since the drying time of the acoustic fini
sh
is much more than 8 hours, there is no need for
rushing.
9
Trowel first layer of Acoustic Finish with
plastic Trowel No. 958 from Pajarito Tools.
(Trowel also available from DEKOZELL)
We recommend to apply the acoustic finish in two
layers wet-in-wet without
intermediate drying.
If a cost efficient structured surface of the
DEKOZELL
®
Acoustic Finisch is favoured, only the
first layer of rendered finish needs to be troweled
,
the second layer will be neatly sprayed only.
If a smooth surface of the DEKOZELL
®
Acoustic
Finisch is favoured, of course also the second
layer needs to be troweled.
If the ultimate supersmooth surface is favoured,
apply one bag of DEKOZELL
®
Acoustic Finish on
no more than 5m² in order to have enough dry film
thickness available for sanding process after
drying.
10
The easiest way to trowel DEKOZELL
®
:
Wet the trowel in water directly prior to use. Hold
trowel relaxed between first two fingers and
thumb. Trowel is always hold in a pitch close to ze
ro degrees, this pitch never changes. Position
trowel at the edge of surface with outstretched arm
. Pull up trowel gently and softly without any
force or pressure
to your body. Stop pulling as soon as lower arm is
in vertical position and lift of
the trowel from the surface in same pitch as starte
d. Stretch out arm again and continue trowel
process – no need to clean up the trowel or wet it
again if all done correctly. Sound a bit
complicated, but within 5 minutes practise usually
the process is understood. To trowel
DEKOZELL
®
is different from other plasters or finishes, but
actually much easier and faster.
11
.
Ensure for good drying conditions
after
DEKOZELL
®
Acoustic Finish is applied.
Blowers and electric dehumidifiers can be used to
speed up drying process. Especially when
ultrasmooth surface shall be obtained anyway
airstream of blowers can be headed directly
towards the acoustic finish.
However, if a cost effective structured surface of
the DEKOZELL
®
Acoustic Finish is favored,
blowers shall be orientated with indirect airstream
in order to avoid differences in texture of surfac
e
during drying process.
Make sure drying time of
DEKOZELL
®
Acoustic Finish will take not longer than 3-4
days.
12
Polishing grinding for ultrasmooth surface
Use disk sander with sandpaper grit P40 for
rough finishing in order to obtain speed in
process prior to polishing. However, be
sure to have enough dry layer thickness of
DEKOZELL
®
Acoustic Finish applied.
Use the lightweight random orbital sander “Mirka
DEROS CV-650” and Abranet grit P320 in order to
obtain the smoothes acoustic render surface
available on the market. The DEROS can be
purchased from DEKOZELL if required.
Using the Mirka DEROS and Abranet P320 the
sanding process is absolutely dust free – as long
as you attach to the sander also a vacuum cleaner
and operate it with a dust bag inside!
In order to refresh contaminated surfaces simply
apply this Polish step again any time in the future
.
Only a minimum amount of dry layer thickness will
be consumed during this refresh process once the
surface has been already grinded sometime in the
past.
A new layer of DEKOZELL
®
Acoustic Finish can
be applied at any time in the future directly on th
e
old layer – the only seamless acoustic system
available on the market which virtually lasts
forever!
Never paint the DEKOZELL surface with
ordinary interior paint – this will seal off the
sound transparency.
If accidentally painted,
simply remove paint with this polishing step.
In order to obtain speed in grinding process, a
rough finishing using disk sander and sandpaper
grit size P40 can be applied prior to polishing wit
h
random orbital sander and Abranet grid P320.
Then the polish steps takes only 1-2 minutes,
since the polishing is just used to remove the
grinding marks from the disk sander.
Have always a vacuum cleaner attached to
grinding equipment. Use vacuum cleaner always
with dust bag inserted.
