A New Solution for Moisture-Resistant, Efficient and Eco-Friendly Renovations
——Moisture-resistant, zero-expansion, industrialized flooring solutions for modular installation
In traditional home decoration, solid wood flooring is favored for its natural texture, but its susceptibility to moisture, installation complexity, maintenance costs and other issues also give many people headaches. Nowadays, a new type of material – PP honeycomb panel, which has the advantages of moisture-proof, extremely lightweight, convenient construction, etc., is becoming an excellent alternative to solid wood flooring. In this article, we will analyze how PP honeycomb panel can bring better solutions for home and commercial space by combining material characteristics and construction cases.
Structural Defects of Traditional Solid Wood Flooring
In 2023, a hardcover property was delivered after the rights incident is typical: 137 owners of solid wood flooring in the home within half a year appeared moldy warping, the root cause is the wood’s natural moisture content of 12%-18% and the average annual humidity of 80% of the environment in the south of the irreconcilable contradiction. This exposed the fatal shortcomings of the traditional program:
High humidity sensitivity: wood at a temperature of 30 ℃, humidity 80% of the environment, due to changes in moisture content caused by the expansion coefficient of 0.15mm / (m-% RH), the expansion of up to 1.5-3mm per linear meter.
Inefficient installation: the keel structure needs to be cut and calibrated on site, and the daily paving volume of a single worker is only 10-20 square meters.
Soaring maintenance costs: rainy season return rate of more than 40%, the average annual maintenance costs of 7 USD/m²
Analysis of the Advantages of PP Honeycomb Panels
Fully plasticized honeycomb core: PP virgin material honeycomb structure, realizing 24% light weight, acid and alkali salt spray corrosion resistance.
Hot melt composite process: three-layer co-extrusion casting technology combined with ultrasonic welding, interlayer peel strength ≥ 18N/cm (ASTM D1876 standard).
Low-temperature adaptability: -40 ℃ low-temperature impact test without cracking deformation.
Eco-renewable: PP material recycling rate ≥95%, VOC release <0.02mg/m³ (beyond the highest level of EN 717-1).
| Performance Indicators | Solid Wood Floor (Oak) | PP Honeycomb Panel System |
| Density (kg/m³) | 650-750 | 45~60 |
| Water Absorption (%/24h) | 8~12 | ≤0.3 |
| Thermal Conductivity (W/m·K) | 0.14 | 0.032 |
| Flexural Strength (MPa) | 75~90 | Transverse: 18 / Longitudinal: 22 |
Data Source: ASTM D1037 Standard Test Method for Evaluating Properties of Wood-Based Fiber and Particle Panel Materials.
Why Choose PP Honeycomb Panels Instead of Solid Wood Flooring?
Completely solve the problem of damp-proofing
Solid wood flooring is prone to deformation and mildew in humid environments, while PP honeycomb panel (polypropylene honeycomb panel) has a core material of waterproof plastic, with a hollow design of honeycomb structure to isolate water vapor penetration. Whether it is rainy season, basement, or wet area such as kitchen or bathroom, it can be used stably for a long time.
Oversize paving saves time and effort
PP honeycomb panel single board size up to 1.2 meters × 2.4 meters, far more than the traditional wood flooring single area. Laying the boards flat reduces the number of joints, and with the screws directly fixing the base without the need for a keel frame, it saves more than 50% of labor and time costs. In addition, its lightweight characteristics (density of about 120kg/m³) further reduces the difficulty of transportation and construction.
Lightweight and high load-bearing, eco-friendly and sustainable
PP honeycomb density is only 1/3 of that of solid wood, but with excellent load-bearing capacity (can carry ≥500kg/㎡, impact strength ≤0.6kgf-m/cm², data source: Labs of CAPO). The material can be 100% recycled and no formaldehyde is released during the production process, which is in line with the trend of green decoration.
PP Honeycomb Panel Floor Construction Process: 4 Simple Steps to Complete the Pavement
Base layer treatment
The ground should be flat and free of debris, if the old ground is damaged, a thin layer of cement self-leveling can be paved. The water content of concrete should be <4%, and the error of flatness should be ≤3mm/2m.
Leveling by laser leveling instrument (error ≤2mm/3m).
Honeycomb panel fixing
Lay the PP honeycomb panel flat on the ground according to the specification of 1.2×2.4 meters, and fix it along the edge and at the middle point directly using rust-proof screws (the spacing is recommended to be 30-40cm). Use electric drill with torque adjustment (torque setting 1.8-2.2N-m) 304 stainless steel self-tapping screws (φ4.2×25mm) to penetrate and fix.
Seam treatment
Fill the gaps between panels with waterproof glue or special UV sealing strips to further enhance moisture resistance. Polymer caulking adhesive injection curing (modulus of elasticity ≥5MPa).
Finally laying 2mm thick PVC floor leather (or Vinyl finish), the surface wear-resistant layer of 0.7mm. floor leather colorful, can be imitation wood grain, marble and other effects, taking into account the beauty and durability.
PP Honeycomb Panel Application Scenarios
Commercial space: shopping malls, exhibition halls and other places that require quick construction and high traffic.
Old house remodeling: no need to remove the original ground, directly covering the pavement, saving costs.
Special environment: basements, warehouses, temporary buildings and other scenes with high requirements for moisture resistance and light weight.
Transportation industry: caravan floor, pickup truck camper, teardrop trailer, box truck body.
- Thickness: 32mm
- Facing layer: Vinyl leather
- Area weight: 4.83kg/m²
- Core density: 100kg/m³
- Thickness: 18mm
- Facing layer: Wood grain pvc film
- Area weight: 4.3kg/m²
- Core density: 120kg/m³
Advantages over Traditional Solid Wood Flooring
- Superior moisture resistance
Passed ASTM D1037 immersion test: 72 hours water absorption and expansion rate <0.08%.
Can be used in 95% RH humidity environment for a long time, completely solve the problem of floor arching. Construction efficiency increased by 80%.
- Modular installation
No keel, self-tapping screws directly fixed (spacing 600mm x 600mm), single board covering 2.88 square meters, 5 person team daily paving volume up to 500 square meters.
- Extreme flatness standard
The overall flatness error is ≤1.5mm/3m (much higher than the national standard of 3mm/2m), and PVC flooring leather can be laid directly without the need for underlayment.
- Full life cycle cost reduction
Material loss rate <3% (solid wood flooring up to 15%).
Zero-maintenance design: 50-year metal fatigue test strength retention rate of >90%.
| Item | PP Honeycomb Panel + Flooring Film | Solid Wood Floor |
| Moisture Resistance | Completely waterproof, zero deformation | Prone to moisture and mold |
| Construction Period | 1-2 days (large panel direct installation) | 3-5 days (requires underlayment) |
| Maintenance Cost | Maintenance-free, localized replacement for damaged surfaces | Regular waxing and insect treatment required |
| Environmental Friendliness | Formaldehyde-free, recyclable | May contain adhesives, difficult to degrade |
Technical Support
CarbodyGroup Global New Material Solutions: https://carbodygroup.com/honeycomb-sandwich-panel/
User FAQs
Can PP honeycomb panels be laid directly on tiles or wooden floors?
Yes, it is possible! Honeycomb panels can be used as a base layer instead of a keel, and the surface layer can be paved with ceramic tiles (which need to be thinly applied), wood flooring or floor leather, which is flexible and adaptable to a variety of styles.
What is the service life?
PP honeycomb panels are corrosion and aging resistant, with a service life of more than 15 years in indoor environments (data support: CarbodyGroup material durability testing)
How economical is PP honeycomb panel flooring?
PP honeycomb panels cost about 40% less per unit than high quality solid wood;
Conclusion
PP honeycomb panels are redefining the standard of floor finishes thanks to their moisture-resistant, efficient and environmentally friendly properties. Whether it’s a homeowner looking for a cost-effective solution or a contractor needing to shorten construction time, this innovative material offers a better solution. Choosing PP honeycomb panel is not only choosing a new material, but also choosing an efficient and sustainable lifestyle.
Consult with a PP honeycomb flooring supplier today for PP honeycomb decking solutions to start your smart renovation era!
