Warmboard R User Manual
R
For assistance call
1.877.338.5493
1
05.18
Warmboard-R
installation guide
2
Table of Contents
Setup and preparation Hardwood and tile installation Carpet, other flooring, temperature
guide and R–values
10 important installation highlights Page 3
Approved tubing list Page 4
Necessary tools Page 5
Choosing the correct router Page 6
Custom routing Page 7
Panel types Page 8
Example of panel/tubing design Page 9
Installing over existing subfloor Page 10
Installing over concrete slab Page 11
Tubing installation Page 13
Installing solid wood flooring Page 16
Hardwood manufacturers Page 18
Installing traditional strip and Page 19
plank hardwood
Installing engineered, laminate, Page 21
and bamboo flooring
Installing tile Page 23
Tile resources Page 31
Installing carpet Page 32
Carpet and padding R-values Page 33
Installing cork flooring Page 34
Installing vinyl Page 35
Installing linoleum Page 36
Finish floor R-values Page 37
Required water temp chart Page 38
For assistance call
1.877.338.5493
10 important installation
highlights
Read these highlights before proceeding. They will save you time and hassle in the long run.
3
1. We recommend the existing subfloor to
be reasonably smooth and flat prior to the
installation of Warmboard–R. Inspect for
squeaks and refasten to joists if necessary.
2. The existing subfloor needs to be dry prior to the
Warmboard–R installation. Warmboard–R cannot
be exposed to rain before or after installation.
3. Use the provided alignment pins when fastening
the Warmboard–R panel.
4. ONLY use tubing approved by Warmboard, Inc.
Silicone or other types of adhesives should not
be used on tubing.
5. Tubing layouts for Warmboard–R can be quite
flexible. Make field revisions as needed. Do not
exceed 300 linear feet per loop.
6. Custom routes require a 1
router minimum. A Porter Cable router will
interface with the template guides provided by
Warmboard, Inc. Do not attempt a custom route
without the proper template guide attached to
the router (see page 6).
7. The Warmboard–R heating system (and the
entire radiant industry) requires the surface
temperature of the finished floors not to
exceed 85ºF.
8. When Warmboard–R is being installed over
a crawl space or existing subfloor, a minimum
of R-19 insulation is required underneath the
panels to prevent downward heat loss.
9. Review the installation manual before installing
finish floors
10. Call us if you have any questions:
1.877.338.5493
1
/
horsepower
2
CAUTION!
Warmboard–R panels must NOT be exposed
to water or excess moisture.
Approved tubing list
These are the tubing types/brands approved for use with Warmboard products.
Select ONLY from the tubing listed below. This will ensure a silent interface between the pex tubing and the aluminum groove. Installing other types of tubing
may create a ticking noise as the tubing expands during operation. This noise is created by the outer layer of the EVOH barrier rubbing against the aluminum.
Warmboard Inc. can also supply tubing and manifolds for your project. Ask your Project Manager for details.
4
PEX Aluminum PEX tubing, 1/2" ID
u
AIM: PEX-AL-PEX
u
Allied Pipe Systems: PEX-AL-PEX
u
Aqua Therm: PEX-AL-PEX
u
Bluefin: PEX-AL-PEX
u
ComfortPro: PEX-AL-PEX
u
EHT (Efficient Heating Technology):
u
Everhot: PEX-AL-PEX
u
Excel: PEX-AL-PEX
u
Henco: PEX-AL-PEX
u
Hydro-flex: PEX-AL-PEX
u
HYDRONX: PEX-AL-PEX
u
Inferno: PEX-AL-PEX
u
Infloor Heating Systems: PEX-AL-PEX
u
Mr. Pex: PEX-AL-PEX
u
RHT: PEX-AL-PE X
u
Rifeng: PEX-AL-PEX
u
Roth: PEX-AL-PEX
PEX-AL-PEX
u
Uponor: Multi-Layer composite tubing (MLC)
PEX-AL-PEX
u
Warmboard PEX: PEX-AL-PEX
u
Watts: PEX-AL-PEX
u
Weil-McLain: PEX-AL-PEX
u
WSD (Willow Springs Distributing) PEX-AL-PEX
u
Zurn Alumicor: PEX-AL-PEX
Standard Barrier tubing, 1/2" ID
u
M r. Pex
u
Rehau Raupex Oxygen Barrier
(manufactured after 3/8/11)
u
ThermaPEX (LK PEX)
u
Uponor Helio PEX
u
Uponor Wirsbo hePEX
u
ViegaPEX Barrier
u
Watts RadiantPEX+
PERT tubing, 1/2" ID
u
Infloor Heating Systems: InfloorPERT
u
Oil Creek Plastics: HEATFLEX pipe
u
Roth: X-PERT S5, 5 layer
u
Watts: RadiantPERT
u
Zurn: hy-PE-RTube
Viega Fostapex is not approved, the diameter is too
large for the Warmboard groove.
CAUTION!
DO NOT USE silicone or other adhesives in the
tubing channels.
Necessary tools
For assistance call
1.877.338.5493
5
Installation kit includes
(supplied with each order)
u
3 Custom routing templates/guides (wood)
5
u
1 Router bit,
u
2 Alignment pins
u
1 Porter Cable template guide
u
1 Porter Cable guide lock nut
/
"
8
Additional materials and tools
(for on-site use)
u
Circular saw, carbide blade
1
u
Porter Cable router, 1
u
Electrician nailing plates
u
Heavy roller (typically a linoleum roller)
u
Warmboard approved tubing
u
Shop vacuum
u
Drill motor with a 1
u
PEX tubing cutter
u
Felt tip marking pen
u
Warmboard panel and tubing plans
u
Tubing un-coiler
u
4" grinder or dremel
Warmboard, Inc. can supply tubing and manifolds
at very competitive prices. Ask your Project Manager
for details.
/
horsepower minimum required
2
1
/
" drill bit
4
Choosing the correct router
NOTE
Not all Porter Cable sub-bases interface
properly with the Warmboard supplied
Porter Cable metal template guides.
1
A minimum 1
size of the metal template guide is 1" OD, designed
for Porter Cable routers and accessories only.
/
horsepower router is required. The
2
6
This photo shows the correct templet guides to use
with the Porter Cable router. These templet guides
are supplied by Warmboard.
This photo shows the correct sub-base and the
supplied metal templet guides installed.
CAUTION!
This Porter Cable router DOES NOT interface with
our supplied template guide and will not work to
create custom routes.
Custom routing
Check list
u
Review all the tubing layout plans. Using a felt tip marker
and the provided wood templates, mark all areas on the
Warmboard–R panel that will require custom routing.
u
Prepare router with router bit, template guide and
template guide lock nut.
The Porter Cable router is not provided. A minimum
1
/
1
horsepower is required.
2
Procedure
For assistance call
1.877.338.5493
7
u
Place the appropriate custom routing template over the
area to be routed
u
Fasten with 3 screws to secure the wooden template
in position
u
Ensure that the router bit and metal template guide are
properly installed, then proceed with the router
u
When the route is complete, remove the template guide
and use 4" grinder or deburring tool to remove aluminum
burrs to ensure that entire area is smooth in preparation
for tubing installation
Visit warmboard.com/videos for further instructions.
5
/
" Router Bit
8
Temp l ate Guide GuideLock Nut
Panel types
8
7
There 2 panel types of Warmboard–R panels. Each panel measures 23
Panels are made from OSB and are square-edged. Filler panels are also available.
/
" W x 47
8
RT RS
7
/
" L x
8
13
/
" H.
16
Turn Panel Straight Panel
NOTE Read all instructions before beginning the installation process.
Review supplied working drawings including floor plan dimensions, before installation.
Example of panel and
tubing design
For assistance call
1.877.338.5493
9
Warmboard does encourage confident contractors
and homeowners to draw their own panel and tubing
shop drawings. We recommend loop lengths of 300
foot maximum, from supply to return manifold.
The modular design of the Warmboard–R panel
allows opportunity for little or no custom routing.
If the finish floor is a nail down hardwood,
Warmboard–R panel should install perpendicular
to the hardwood planks.
If this is not an endeavor you want to take on,
Warmboard, Inc. can provide the shop drawings.
Panel layout example Tubing layout example
Panel layout for this
18.5 ft
RT RT RT RT RT RT RT
RT RS RS RS RS RS
RS RS RS RS RS RS RT
RS RS RS RS RS RS RT
RTRTRTRTRTRTRT
section starts here.
RT
9.75 ft
6 ft
9.75 ft
Fireplace
18.5 ft
RT RT RT RT RT RT RT
RT RS RS RS RS RS
1.2
ZONE 1
RS RS RS RS RS RS RT
170
RS RS RS RS RS RS RT
RTRTRTRTRTRTRT
1.1
ZONE 1
210
Panel layout for this
section starts here.
RT
9.75 ft
6 ft
9.75 ft
Fireplace
Installing over existing subfloor
10
It is essential that the existing subfloor is both
flat and smooth before the installation of
Warmboard–R. Inspect the subfloor for evenness
along the joists and flatness between the joists.
If necessary, sand the subfloor, install extra
blocking below the subfloor, and refasten the
subfloor to even areas. Also, inspect for squeaks
and refasten with decking screws as necessary.
The subfloor and Warmboard– R need to be dry. The
Warmboard–R cannot be exposed to any rain before
or after installation.
Cutting and installing Warmboard–R is very
straightforward. The panels can be trimmed with
a standard skill or table saw and will rip just like
ordinary OSB. It is best to cut the panels with the
aluminum side down. We recommend two different
options for attaching the panels to the subfloor.
It is crucial to use the provided alignment pins to line
up the channels from panel to panel.
Screw fasteners methods
1
Use a 8 x 1
R4 screw with a top
at Home Depot). Using an equivalent product is
acceptable. Fasten with in a pattern of 3 rows of 4.
u
No pre-drilling required
u
Self counter sinking
u
No adhesive needed
/
" “GRK Uber Grade” multi-purpose
2
1
/
" smooth shank (available
2
Nail and glue method
Using a construction adhesive designed for bonding
OSB and plywood, such as “Loctite PL Wood” is an
excellent choice. The use of an equal product is also
acceptable. Follow all directions as specified by the
adhesive manufacture.
For nailing, use a ring shank or a screw nail.
To determine the appropriate length of the nail to
use, evaluate existing thickness of subfloor and add
13
/
". This will be the minimum length required.
16
Fasten nails with a pattern of 3 rows of 4.
Installing over concrete slab
For assistance call
1.877.338.5493
11
Benefits
Installing Warmboard–R over an existing concrete
slab can retrofit a basement or home remodel with a
state of the art radiant floor heating system. Finish
floor options include the broad range available with
a Warmboard system such as hardwood, tile, carpet,
vinyl and linoleum.
Concrete slab requirements
The existing slab must be level and flat. A newly
poured slab needs to be well cured which requires
a minimum of 30 days. A moisture test should be
conducted prior to installation to ensure the slab
is properly cured. The slab must have sufficient
drainage from rain and snow on a year round
basis. If the Warmboard–R panels are exposed
to any standing water or any moisture intrusion,
the wood will rot. Do not use Warmboard–R if
these environmental conditions are possible.
When Warmboard–R is being installed over an
existing slab, it is crucial for the panels never to
be exposed to weather. After installation, if the
Warmboard panels are exposed to rain or snow,
the moisture will be trapped in the panel and
wood rot will take place.
Testing for moisture
There are several possible methods by which to test
the moisture content of a newly poured slab, the
simplest being “The Plastic Sheet Method” (ASTM
D 4263-83). For this method, seal an 18" x 18"
square of clear plastic sheet to the slab with tape
on all 4 sides. If, after 16 hours, any condensation
is found on the underside of the plastic or if the
surface of the concrete is darkened, the concrete
is considered too wet for coating application.
Do not allow the sheet to come in contact with
direct sunlight or excessive heat.
It is possible for this particular method to yield a
false result, giving the impression that the slab is
fully cured, when in fact it still contains moisture.
For example, in cooler conditions, the concrete
may retain its moisture and fail to condense on
the plastic. However, an obvious appearance of
moisture in this method almost always indicates
excessive moisture.
With the Plastic Sheet Method, the best way to
ensure a reliable result is to make sure that the
surface temperatures and ambient conditions during
the test are very similar to those present after the
Warmboard panels are installed.
If no moisture test is conducted, we recommend
giving a newly poured slab 90 days to cure fully.
Installation method 1
Install a vapor retarder directly to the slab.
We recommend either a 6 or 10-mil polyethylene
overlapped two feet (2') at the seams. Continue with
Warmboard–R panel installation with the use of
Tapcon concrete fasteners or Split Drive Anchors.
We recommend a maximum of 9 fasteners for
each panel.
Installation method 2
Install a 6- or 10-mil polyethylene vapor retarder
directly to the slab, overlapping two feet (2') at the
seams. Next, install the
or Homasote 440 Soundbarrier over the entire slab
(adding a R-value of 1.2). Gap all Homasote panels
3
/
" from all adjoining panels and
16
Use fasteners to attach the entire assemble to slab.
We recommend 9 fasteners per panel. Review the
installation instructions of the Homasote Comfort
Base or the 440 Soundbarrier at homasote.com
Before installation of a Tapcon fastener, drill a pilot
1
/
hole
" deeper than the Tapcon will reach. Draw the
2
bit in and out of the pilot hole repeatedly to loosen
excess material. Then remove the excess using a
shop vacuum.
1
/
" Homasote Comfort Base
2
3
/
" from walls.
8
12
Fastening pattern for
Warmboard–R over concrete
Split drive anchor OR
Tapcon concrete screw
13
/
" Warmboard–R
16
6-mil polyethylene
vapor barrier
1" min
Concrete slab
We highly recommend flat head split drive anchors.
They will save many hours, or days, of labor by
comparison.
Concrete drilling should be done with panels in
place. Predrilling the panels prior to installation is
not recommended.
Concrete drilling should be done with a heavy duty
1
roto hammer drill and a high quality
/
" masonry
4
drill bit. Use a 3 lb. sledge hammer to drive the split
drive anchor through the predrilled panel and into the
concrete.
1
1
/
Use a
/
" x 2
" flat head split drive anchor.
4
2
Split drive anchors can be difficult to find in common
retail stores. We suggest visiting confast.com
or calling 888-498-5747.
Before installation of a Tapcon fastener, drill a pilot
hole 1/2" deeper than the Tapcon will reach. Draw
the bit in and out of the pilot hole repeatedly to
loosen excess material. Remove the excess using
a shop vacuum.
Predrill with Warmboard–R in place using a high-quality
1
masonr y bit. Drilling depth should be
/
" deeper than
2
the required specication without drilling through the
slab. All concrete drilling should be done with a heavy
duty rotary hammer drill.
Preferred method
1
1
/
/
2
" x
"Flat Head Split Drive Anchor
2
4
1
/
Use
" high-quality masonr y bit
4
1
1
/
/
" x
" Flat Head Tapcon Concrete Screw
2
4
4
3
/
Use
" high-quality masonr y bit
16
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