Wall Installation Guide

PRE-INSTALLATION PREPARATION

Acclimatisation of Wall Panels

It is essential to acclimatise Concreate Wall Panels prior to installation. Providing that site conditions are appropriate before the panels arrive, the panels should be stored in packs prior to installing, in warm dry conditions (i.e. similar to those which will prevail when the space will be occupied is and in use: 45 to 65% RH). The panels should be stored in the room(s) where they are to be installed for a minimum of 72 hours to allow them to acclimatise to the ambient temperature and humidity. In order to protect the product, it is recommended that the panels are kept in the packaging until installation commences.

Usage

Concreate Wall Panels may be applied to any flat surface including, walls, ceilings, bespoke furniture, doors, tables, counters and stair risers. With Concreate wall adhesive the panels will bond easily to gypsum board / drywall, plywood, cement board and concrete surfaces. Concrete surfaces must be sound and dry. It is recommended that concrete surfaces be tested. Concrete surfaces at ground level or below must contain an effective moisture membrane to protect panels from ground water.

Surface Preparation

Concreate wall panels must be installed over a flat, dry substrate that has been vacuum cleaned and is completely dust-free. Failure to properly clean the surface may inhibit the adhesive from properly adhering, causing the planks to shift. If necessary a primer may be used.

Layout Considerations

Panels can be installed in any combination or pattern and can be cut to make bespoke sizes as required.

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Consistently Inconsistent

Concreate is a natural surface with tonal and colour variation. To achieve the desired mix of colours, shades and other characteristics in the final wall, and avoid clusters of similar colour shades, the contents of multiple packs should be mixed during installation. Samples must be taken as a guide only and colour/shade and other characteristics will vary. Before installation commences rack out a small section of boards for the client approval. This product may include up to 3-5% of boards which do not meet the usual tolerances or grade, which should be defect cut or set aside as waste.

Installation Instruction

NOTE: Before Concreate wall panels can be delivered to the job site, all wet trades (e.g. concrete, plastering, and decorating) must be finished and the building must be weather tight and thoroughly dried out.

**The installer is the last line of quality control. DO NOT INSTALL BOARDS WITH OBVIOUS DEFECTS. If unsure contact the team.

  1. OPEN PACKAGES
    (Take care not to damage corners and edges.)
  2. LAYOUT / COMPOSITION OF INDIVIDUAL PANELS
    (Refer to Pre-installation Preparation ‘Consistently Inconsistent’ section of these guidelines)
  3. SNAP POINTS FOR LAYOUT AND SELECT STARTING POINT FOR LAYOUT
  4. CUTTING CONCRETE WALL PANELS
    (Utilize the ‘Score and Snap’ method, as shown on the left, or standard construction cutting methods may be employed. See additional informa- tion under Safety Recommendations)
  5. SAND ANY RAGGED EDGES WITH A SANDING BLOCK
  6. APPLY ADHESIVE WITH A HEAVY DUTY CAULK GUN TO FIT CONCERT WALL ADHESIVE CARTRIDGES
  7. PLACE CONCREATE WALL PANEL AND APPLY EVEN PRESSURE ACROSS THE WHOLE SURFACE TO ENSURE GOOD ADHESION
  8. REPEAT STEPS WITH SUBSEQUENT PANELS, MAKING SURE TO BE CAREFUL WITH CORNERS AND EDGES
    (If necessary, use rubber mallet and rubber tapping blocks to maneuver panels into proper and tight fitment with one another.)
  9. USE CONCREATE REPAIR KIT MIXTURE TO FILL AND SEAL SEAMS BETWEEN PANELS IF REQUIRED
    (Refer to Use Instructions for proper use of Concreate Repair Kit.)

Tips:

  • When installing wall panels, check occasional panels after placement to ensure that they are fully bonded to the substrate.
  • If loose, a pneumatic 23 gauge nail gun may be used to tack panels into place. Tiny nail holes may need to be filled with Concreate Repair Kit.
  • When protecting the installed surface from other trades, apply tape ONLY to the protective material.
  • DO NOT apply tape directly on Concreate wall panel surface.

NOTE:

Patterns may also be rotated ninety degrees to create interesting and dynamic spaces. Concreate invites designers to be creative in layouts of flooring planks. These suggestions are simply a starting point!

SAFETY RECOMMENDATIONS

Cutting Concreate Wall Panels:

Concreate wall panels may be cut either with the Score and Snap method or a dry diamond tipped saw.

SCORE AND SNAP 

(Shown Left): 1 – Score the surface of the panel with a utility knife, using a straight edge as the guide. 2 – Place panel along a straight, flat surface with score seam facing up and aligned with the edge. 3 – Secure the edge resting on the surface and gently apply pressure to the free, overhanging edge. Panel should ‘snap’ along score-line. 4 – Sand any ragged edges with a sanding block prior to installation.

CUTTING:

When cutting Concreate wall panels around intricate or detailed objects, a jigsaw or other small hand-held cutting devices may be employed as long as the bit/blade is diamond tipped and intended for use with concrete. Always secure panel to working surface prior to making detailed cuts. It is recommended that any power activated tools be connected to an appropriate dust evacuation system when cutting dry.

Proper Personal Protective Equipment (PPE) must be worn at all times to protect from injury during installation of this product. Personal Protective Equipment (PPE) includes, but is not limited to the following: hard hat, eye protection, ear protection, respiratory protection and work gloves.

POST INSTALLATION CARE

Please see Care and Maintenance Guidelines for the proper way to care for your new Concreate wall panels.

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