SONOPHONE®
Spray Applied Acoustic Plasters
Sonophone™ is a spray-applied acoustic plaster specially designed for interior sound absorption applications. Sonophone™ provides an attractive white surface.
Sonophone™ is a cementitious spray-compound that requires only the addition of water on the jobsite to form consistent pumpable slurry.
It is ideal for new construction, repair or remodeling work. It may be applied over gypsum panel, concrete base coat plaster on steel surfaces. Uses include convention centers, schools, education and religious facilities.
Sonophone™ is a cementitious spray-compound that requires only the addition of water on the jobsite to form consistent pumpable slurry.
It is ideal for new construction, repair or remodeling work. It may be applied over gypsum panel, concrete base coat plaster on steel surfaces. Uses include convention centers, schools, education and religious facilities.
Products
Sound Absorption
Instructions
GENERAL REQUIREMENT: ALL SURFACES MUST BE CLEAN AND FREE OF DUST, GREASE, OIL, RUST, LOOSE SCALE, EFFLORESCENCE OR ANY SUBSTANCE WHICH WOULD AFFECT APPEARANCE OR PERFORMANCE OF SONOPHONE-1.
EQUIPMENT
The equipment used to apply Sonophone-1 is typically a small rotor/stator type pump, equipped with a one or two bag paddle type mixer. This type of equipment includes pumps such as the Putzmeister P11 & S5, BMat, and plaster mixers.
Continuous mixer/pumps can also be used. Examples of this type of equipment include models as G4, G5 from PFT, Turbosol, ISO P5 from ISOL Industries etc ...
For larger jobs piston pumps such SUNSPRAY 320 can be employed.
MIXING
Sonophone-1 requires 24 (+- 2) liters of water per bag of material. 22 liters of mix water should be used when drying rate and hangability are concerns, on jobs were drying rate and hangability are less of a concern 26 liters should be used. Higher levels of mix water will improve yield and increase pumping rate.
Sonophone-1 should be mixed for 2 - 3 minutes. Keep in mind that the longer the mix the lower the final density will be. As the final density goes down the yield of Sonophone -1 will increase.
The mixer density of Sonophone -1 mixed with 20 - 24 liters of water and mixed for 2 - 3 minutes will be in the 609- 721 kg/m³ density range.
Sonophone-1 set time has been adjusted to set in 2 - 3 hours.
Material should not be mixed unless it can be applied within 1 hours after it has been mixed. Because Sonophone-1 is a bright white, mixed with any contamination from darker materials will result in staining of the Sonophone-1 . For this reason all equipment should be cleaned thoroughly prior to mixing Sonophone-1.
APPLICATION
The most important aspect of SONOPHONE-1 application is the texture of the material. It is important that the texture desired by the architect or building owner is the texture that is being applied . The texture can vary greatly depending on air atomization, orifice size and spray technique, the most important being air atomization. The Nozzle air should be in the 1,5 - 2 Bar range. The higher the air the finer the texture of the Sonophone. There is however, a price to pay for a finer texture. The higher atomization air increases the density of the Sonophone-1 which results in a lower yield. A 13 mm orifice is suggested for most applications. However, if high air pressure is being used in order to achieve a finer texture then a 10 mm orifice will yield better results.
SPRAY TECHNIQUE
In order to achieve aesthetically pleasing results some general techniques should be adhered to. These techniques include the following:
1. Always keep the spray gun moving in long sweeping passes without lingering in anyone spot.
2. Build up thickness using 6 mm, (or lighter), perpendicular passes rather than attempting to build the thickness in a single pass.
Although Sonophone-1 can be applied up to 13 mm in one pass on horizontal surfaces, better results will be achieved using the multiple perpendicular pass method.
3. For thickness over 25 mm, up to 50 mm, a fine final texture will be obtain if you smooth lightly the previous coat (before the ultimate 5-6 mm final spray, using smaller orifice) with a stainless steel trowel or a plastic roller (maximum width 50 - 70 cm or over).
The waiting time before you press Sonophone-1 will depend of the result you want. Usually before 10 and 30 minutes. This finishing method can be also used for a final coat.
4. If there is a predominate light source entering the area to be covered then the majority of the Sonophone-1 should be applied in passes parallel with the direction of the light. By doing this, any ridges that develop in the material while spraying will not shadow.
HAND WORKING
Spray application of Sonophone with appropriate air pressure will give you a finished product which meets published density, yield-per bag, compressive strength and bond-to- substrate characteristics.
If trowel application of the Sonophone-1 scratch coat is desired to meet jobsite production requirements, the physical properties noted above may be significantly reduced.
If a troweled finish is desired to meet visual aesthetic requirements of the project, Grace suggests that Sonophone-1 be spray applied and then troweled or rolled with the paint roller. Do not expect a plaster-smooth, seamless surface when Sonophone-1 is hand worked.
DRYING
As with all plaster based materials, adequate ventilation should be provided in order to allow Sonophone to dry as soon as possible.
CONTROL JOINTS
Conventional plastering industry standards regarding placement of control joints should be followed when applying Sonophone-1. The use of control joints combats the effects of dimensional changes caused by changes in humidity and temperature.
SUBSTRATE PREPARATION
Because Sonophone-1 is a wall/ceiling finish material, the texture, color and bond of the in-place product are of great concern to the owner and designer. For this reason, the time and effort spent in preparation of the substrates to receive Sonophone, are good investments on the part of the applicator.
Substrate, Texture
Although minor surface variations in the substrates will be hidden by the coating of Sonophone-1 which you put in place, significant variations in the substrates surface will telegraph through to the Sonophone-1 surface. For this reason on concrete substrates it is necessary to grind down projections and edges which remain after removal of concrete forms, and to patch holes, cracks or joints. Similarly, gypsum wallboard joints and nails must be finished using conventional joint treatments.
Important point for Wallboard application:
Wallboard substrate must be waterproofed before Sonophone application. This must be done using a specific plasterboard sealant product, 2 crossed coats apply with a paint roller or 2 Gracco / Airless thick coats. Then, EAD primer must be used as bonding agent.
We recommend also to do not use Sonophone-1 over 15 mm thickness on wallboard substrate. Base-coat plaster should be smooth and without voids. Sonophone-1 can be trawled into voids in substrates to create a smooth finish prior to machine application of the required thickness.
Surface Texture
The overall surface texture of Sonophone-1 is dependent on the spray technique employed, the orifice size used and the atomizing air pressure at the nozzle (See section on Application in this brochure).
Color
Sonophone-1 is formulated to provide a white, highly light reflective surface. Rust or stains present on the substrates will bleed through to the surface, resulting in possible rejection by the architect or owner. Stain Killing paints are available and should be applied to all stained, rusted, effloresced, and exposed metal surfaces prior to application of Sonophone-1.
Your equipment housekeeping and maintenance also influence the color of the finished product. All mixing pumping and conveying equipment must be thoroughly cleaned prior to initial job startup and at the end of each day.
Bond to Substrate
Obviously it is important that Sonophone-1 achieve a strong bond to the substrates over which it is being applied. For this reason, the application of a bonding agent is required over gypsum wallboard, concrete and previously painted surfaces. A bonding agent may also be required over some of the available stain killing paints and some of the encapsulates used in asbestos abatement work. Requirements promulgated by Underwriters Laboratories, Inc. are very specific and detailed in this regard. Further information on approved bonding agents is provided later in this section.
Sample
Because the finished appearance of Sonophone is so important, architect and owners will frequently require that a sample be done for approval of surface texture prior to the start of spraying operations. It may be in your best interest to arrange for similar preliminary approval even on jobs where the specification does not require it. For all of the reasons discussed above, one general requirement should guide the application of Sonophone-1 in all applications.
EQUIPMENT
The equipment used to apply Sonophone-1 is typically a small rotor/stator type pump, equipped with a one or two bag paddle type mixer. This type of equipment includes pumps such as the Putzmeister P11 & S5, BMat, and plaster mixers.
Continuous mixer/pumps can also be used. Examples of this type of equipment include models as G4, G5 from PFT, Turbosol, ISO P5 from ISOL Industries etc ...
For larger jobs piston pumps such SUNSPRAY 320 can be employed.
MIXING
Sonophone-1 requires 24 (+- 2) liters of water per bag of material. 22 liters of mix water should be used when drying rate and hangability are concerns, on jobs were drying rate and hangability are less of a concern 26 liters should be used. Higher levels of mix water will improve yield and increase pumping rate.
Sonophone-1 should be mixed for 2 - 3 minutes. Keep in mind that the longer the mix the lower the final density will be. As the final density goes down the yield of Sonophone -1 will increase.
The mixer density of Sonophone -1 mixed with 20 - 24 liters of water and mixed for 2 - 3 minutes will be in the 609- 721 kg/m³ density range.
Sonophone-1 set time has been adjusted to set in 2 - 3 hours.
Material should not be mixed unless it can be applied within 1 hours after it has been mixed. Because Sonophone-1 is a bright white, mixed with any contamination from darker materials will result in staining of the Sonophone-1 . For this reason all equipment should be cleaned thoroughly prior to mixing Sonophone-1.
APPLICATION
The most important aspect of SONOPHONE-1 application is the texture of the material. It is important that the texture desired by the architect or building owner is the texture that is being applied . The texture can vary greatly depending on air atomization, orifice size and spray technique, the most important being air atomization. The Nozzle air should be in the 1,5 - 2 Bar range. The higher the air the finer the texture of the Sonophone. There is however, a price to pay for a finer texture. The higher atomization air increases the density of the Sonophone-1 which results in a lower yield. A 13 mm orifice is suggested for most applications. However, if high air pressure is being used in order to achieve a finer texture then a 10 mm orifice will yield better results.
SPRAY TECHNIQUE
In order to achieve aesthetically pleasing results some general techniques should be adhered to. These techniques include the following:
1. Always keep the spray gun moving in long sweeping passes without lingering in anyone spot.
2. Build up thickness using 6 mm, (or lighter), perpendicular passes rather than attempting to build the thickness in a single pass.
Although Sonophone-1 can be applied up to 13 mm in one pass on horizontal surfaces, better results will be achieved using the multiple perpendicular pass method.
3. For thickness over 25 mm, up to 50 mm, a fine final texture will be obtain if you smooth lightly the previous coat (before the ultimate 5-6 mm final spray, using smaller orifice) with a stainless steel trowel or a plastic roller (maximum width 50 - 70 cm or over).
The waiting time before you press Sonophone-1 will depend of the result you want. Usually before 10 and 30 minutes. This finishing method can be also used for a final coat.
4. If there is a predominate light source entering the area to be covered then the majority of the Sonophone-1 should be applied in passes parallel with the direction of the light. By doing this, any ridges that develop in the material while spraying will not shadow.
HAND WORKING
Spray application of Sonophone with appropriate air pressure will give you a finished product which meets published density, yield-per bag, compressive strength and bond-to- substrate characteristics.
If trowel application of the Sonophone-1 scratch coat is desired to meet jobsite production requirements, the physical properties noted above may be significantly reduced.
If a troweled finish is desired to meet visual aesthetic requirements of the project, Grace suggests that Sonophone-1 be spray applied and then troweled or rolled with the paint roller. Do not expect a plaster-smooth, seamless surface when Sonophone-1 is hand worked.
DRYING
As with all plaster based materials, adequate ventilation should be provided in order to allow Sonophone to dry as soon as possible.
CONTROL JOINTS
Conventional plastering industry standards regarding placement of control joints should be followed when applying Sonophone-1. The use of control joints combats the effects of dimensional changes caused by changes in humidity and temperature.
SUBSTRATE PREPARATION
Because Sonophone-1 is a wall/ceiling finish material, the texture, color and bond of the in-place product are of great concern to the owner and designer. For this reason, the time and effort spent in preparation of the substrates to receive Sonophone, are good investments on the part of the applicator.
Substrate, Texture
Although minor surface variations in the substrates will be hidden by the coating of Sonophone-1 which you put in place, significant variations in the substrates surface will telegraph through to the Sonophone-1 surface. For this reason on concrete substrates it is necessary to grind down projections and edges which remain after removal of concrete forms, and to patch holes, cracks or joints. Similarly, gypsum wallboard joints and nails must be finished using conventional joint treatments.
Important point for Wallboard application:
Wallboard substrate must be waterproofed before Sonophone application. This must be done using a specific plasterboard sealant product, 2 crossed coats apply with a paint roller or 2 Gracco / Airless thick coats. Then, EAD primer must be used as bonding agent.
We recommend also to do not use Sonophone-1 over 15 mm thickness on wallboard substrate. Base-coat plaster should be smooth and without voids. Sonophone-1 can be trawled into voids in substrates to create a smooth finish prior to machine application of the required thickness.
Surface Texture
The overall surface texture of Sonophone-1 is dependent on the spray technique employed, the orifice size used and the atomizing air pressure at the nozzle (See section on Application in this brochure).
Color
Sonophone-1 is formulated to provide a white, highly light reflective surface. Rust or stains present on the substrates will bleed through to the surface, resulting in possible rejection by the architect or owner. Stain Killing paints are available and should be applied to all stained, rusted, effloresced, and exposed metal surfaces prior to application of Sonophone-1.
Your equipment housekeeping and maintenance also influence the color of the finished product. All mixing pumping and conveying equipment must be thoroughly cleaned prior to initial job startup and at the end of each day.
Bond to Substrate
Obviously it is important that Sonophone-1 achieve a strong bond to the substrates over which it is being applied. For this reason, the application of a bonding agent is required over gypsum wallboard, concrete and previously painted surfaces. A bonding agent may also be required over some of the available stain killing paints and some of the encapsulates used in asbestos abatement work. Requirements promulgated by Underwriters Laboratories, Inc. are very specific and detailed in this regard. Further information on approved bonding agents is provided later in this section.
Sample
Because the finished appearance of Sonophone is so important, architect and owners will frequently require that a sample be done for approval of surface texture prior to the start of spraying operations. It may be in your best interest to arrange for similar preliminary approval even on jobs where the specification does not require it. For all of the reasons discussed above, one general requirement should guide the application of Sonophone-1 in all applications.
Referencies
Kirkkonummen kirkko
Kiasma / Helsinki
Wasa Teater / Vaasa
Pielisensuun kirkko / Joensuu
Yle-studio / Pasila
Raision kaupunginkirjasto
Pihkapuiston ala-aste / Helsinki
Vallilan Ammattikoulu / Helsinki
Koskipuiston Elokuvateatteri / Tampere
Porin Promenadikeskus / Pori
Ruskeasuon Ratsastus- ja Liikuntahalli / Helsinki
Old Mill / Turku
Finlayson kehräämö / Forssa
Sokos Ravintola / Oulu
Sokos Ravintola / Oulu
Sokos Ravintola Fransmanni / Jyväskylä
Ravintola Zanzibar / Turku
Espoon keilahalli
Järvenpään sosiaalisairaala III osa
Meilahden sairaala / Helsinki
Turku Port Center
Leppävaaran Uimahalli
Merisotakoulu, Suomenlinna
Kiasma / Helsinki
Wasa Teater / Vaasa
Pielisensuun kirkko / Joensuu
Yle-studio / Pasila
Raision kaupunginkirjasto
Pihkapuiston ala-aste / Helsinki
Vallilan Ammattikoulu / Helsinki
Koskipuiston Elokuvateatteri / Tampere
Porin Promenadikeskus / Pori
Ruskeasuon Ratsastus- ja Liikuntahalli / Helsinki
Old Mill / Turku
Finlayson kehräämö / Forssa
Sokos Ravintola / Oulu
Sokos Ravintola / Oulu
Sokos Ravintola Fransmanni / Jyväskylä
Ravintola Zanzibar / Turku
Espoon keilahalli
Järvenpään sosiaalisairaala III osa
Meilahden sairaala / Helsinki
Turku Port Center
Leppävaaran Uimahalli
Merisotakoulu, Suomenlinna
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