Self-leveling alternatives to gypsum concrete (Gyp-Crete, Pyrofill, Securock) over OSB?




Last Updated February 20, 2016 01:09 AM

Replacement options for < 1.5 inch pour?

Details: Bathroom remodel (new tub, tile wall/floor, toilet, vanity). Old tile floor came up with finger pressure, found that the gypsum concrete underneath was unstable, coming off in large loose pieces, and mildewed. Removed all gypsum concrete in the small bathroom. OSB is in great shape. Supplemental goal to install underfloor radiant heating.

Answers 1

If you have a 1.5” pour why not use fine aggregate cement? If your radiant heat is water tube based tack your tubes to the subfloor and pour. If it is electrical, make sure to follow the MFG recommendations. Some tapes can be bedded in the cement and this helps even out the heat. One tape I used had to be covered and the covering almost doubled the install cost. As long as your cement is not way two wet it will be fine. In my opinion a stronger floor that last the longest.

Ed Beal

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Very slow moving project. Still planning... We're getting by with one batchroom upstairs for now.

Thinking of going with the Ditra. One question though, since the subfloor is only 5/8" tongue-and-groove OSB, and while most of the floor is 16" oc, there is one set of joists that are 24" oc (accommodating duct work). The Ditra handbook specifies min 5/8" over 16" oc, and 3/4" min. over 24" oc. (Ditra-XL). Should I put a layer of plywood (min. thickness?) or a layer of cement board over the OSB? I was thinking plywood, but not sure what would be best.

On the level issue, I think since the real problem is that two adjacent joists are a 1/2" different in height, I think I can put 1/2" plywood over the OSB in the lower section , feather thinset at the point of the drop off, and take the hit on the height transition at the doorway. Seems to be the best approach to getting the smallest transition.

BTW. Thanks to all for all the good...

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Generic Concrete Products with Portland Cement…

Generic Concrete Products with Portland Cement . ... Portland cement concrete products like beams and columns are modeled based on ... on the aggregates and cement …

Alternative Binders for Concrete Other Than Cement

What is Concrete? Cement + Aggregates + Water ??? ... Alternative Binders for Concrete other than Cement Gypsum Concrete: ...

ASTM C/ CM() Standard Specification …

C() Standard Specification for Gypsum Concrete , aggregates, calcined gypsum, gypsum, gypsum concrete ,,

Drying shrinkage cracksPennsylvania State University

Each aggregate and cement type has ... directly to the drying shrinkage of concrete. ... adjustment of the amount of gypsum added to the different cement ...

“Hardness and Durability Characteristics of Mould …

durability and weight of moulds have been found to...

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If you've got a structurally sound substrate and a short timetable, a self-leveling overlayment may be your best option for refurbishing an existing floor in either a home or a commercial establishment. From featheredging to multiple layering, today's quick-curing products are mostly used to even out horizontal surfaces, raise floor levels to match new thresholds or breathe new life into old floors without the fuss and expense of tearing up or troweling over. Most resurfaced areas can be open to foot traffic within two to six hours and to electricians, plumbers and other "trade traffic" in a day.

Some people say self-leveling concrete and self-leveling toppings are the same thing. Others contend self-leveling concrete is used full-depth while toppings are applied to an existing base. Many divide self-leveling concrete into two categories: underlayments that need some type of covering like carpet or tile, and overlayments that can be covered or decoratively finished as a wear...

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Gypsum concrete is a building material used as a floor underlayment used in wood-frame and concrete construction for fire ratings, sound reduction, radiant heating, and floor leveling.[1] It is a mixture of gypsum plaster, Portland cement, and sand.[1] The brand name Gyp-Crete, a Maxxon Corporation trademark, has come into general use as a term for gypsum concrete by construction professionals and architects.[2]


US patent 4,444,925 lists the components of Gyp-Crete® as atmospheric calcined gypsum, sand, water, and small amounts of various additives. Additives listed include polyvinyl alcohol, an extender such as sodium citrate or fly ash, a surfactant such as Colloid defoamer 1513 DD made by Colloids, Inc., and a fluidizer based on sodium or potassium derivatives of naphthalene sulfonate formaldehyde condensate. One example mix is shown below.[3]

The purpose of the polyvinyl alcohol is to prevent the surface of the concrete from becoming...

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I've googled this extensively. What I've found is many people asking the question and very few people giving any actual idea on how to remove the imperfections in OSB.

Laminate requires no more than a 1/16" unevenness over 40", which is exceedingly flat. My guess is a lot--probably even the majority--of laminate jobs installed exceed this. Are they having problems? I don't think so, but possibly could be used to reject a warranty claim.

Anyway, my floors are in good shape mostly, with up to 1/8" over 40" which I intend on ignoring. However, I do have a section with 1/4 or 3/8" (the result of a high joist, which makes either side low). The question is: how to raise those other sides up (sanding down the OSB over that part of the joist is an option, but a lot of work, and could compromise the floor;require re-screwing/nailing).

Ideas online:

1) Leveling compound. Note: a lot of this stuff isn't wood approved and could make a hellacious mess around the walls

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Asbestos tile removal could be a downside. Param is our self leveling concrete which will be applied at numerous thicknesses over VCT leading to vast savings in time and cash. several older buildings have VCT Tile with asbestos. These tiles provided hearth resistance and sturdiness, a high performance function that has continually been in demand. but as time marches on they begin to deteriorate and create a major health risk. once this starts to happen, you would like an answer.
Asbestos tile removal could be a downside. As presently as Tile starts to get removed, particles become mobile making a serious ill health. Health risks embody pneumonoconiosis, a respiratory organ unwellness, that scars the lungs preventing oxygen to enter the blood stream. there’s no cure. alternative diseases include carcinoma and carcinoma.
Removal needs specialists and substantial expense and time. In several cases the price reduces or eliminates the economic viability of removal or...

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Alternatives to paper-backed gypsum board are now available. The following products may be used to replace it and are especially use ful in applications where moisture conditions may promote mold growth:

• Dens Armor Plus is an alternative to regu lar cardboard-backed panels. It is paper less, faced on two sides with a glass mat, and highly mold resistant.

• Magnesium oxide boards: Currently these products are being manufactured in China. They can be used to replace gypsum board, plywood, cement boards, and oriented strand board (OSB). They resist moisture, bugs, fungus, mold, and fire. Products are available in North America under the prod uct names Dragonboard, MagBoard, and Strong-Enviro Board.


Tile is generally an inert and healthful floor, wall, and counter surfacing material. We rec ommend factory-finished tiles that require no further finishing onsite. Many attractive and reasonably priced tiles are rated for com mercial and exterior use....

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