Precast concrete wall panels are increasingly popular in modern architecture and interior design, offering both aesthetic appeal and practical benefits like insulation, fire resistance and durability. Whether you're an experienced contractor or a DIY enthusiast looking to elevate your space, understanding the proper installation process is key to achieving a flawless finish. In this guide, we’ll walk you through the step-by-step process of installing our lightweight paneling designed to be easy to handle while delivering high-performance results.

We recommend using Sika 118 Extreme Grab for glue applications, a powerful adhesive with excellent bonding strength to ensure that the panels are securely mounted. This adhesive is versatile and highly durable, making it ideal for installations in Australia, United States, Middle-East and Europe. Let’s dive into the process!

Tools and Materials You’ll Need:

Before you begin, gather all necessary tools and materials to streamline the installation process:

• FLOAT concrete wall panels
• Sika 118 Extreme Grab adhesive
• Caulking gun (for adhesive application)
• Level
• Tape measure
• Pencil or chalk for marking
• Rubber mallet
• Spacers (optional, for consistent gaps between panels)
• Stud finder (if installing on drywall)
• Angle grinder or masonry saw (if cutting panels to size)
• Protective gear (gloves, goggles)

Step 1: Prepare the Surface

A clean level dust-free surface is critical for the installation of lightweight concrete wall panels. The panels can be installed on various surfaces, including drywall, concrete, and plywood. Here’s how to prep each type of wall:

• Drywall: Ensure that the drywall is flat, clean, and free of dust or debris. Use a stud finder to locate wall studs for additional support when mounting heavier panels.
• Concrete: Clean the concrete wall of any dirt, grease, or dust that could interfere with the adhesive bond. If necessary, use a wire brush or grinder to smooth out uneven spots.
• Plywood: Sand down any rough or uneven areas on the plywood and ensure it’s firmly fixed to the wall. Plywood serves as an ideal substrate for lightweight panels, as it offers excellent adhesive bonding and support.

Make sure the surface is dry, as moisture can compromise the adhesion of the panels.

Step 2: Plan Your Layout

Before you start applying the adhesive, it’s crucial to plan the layout of your concrete panels. Consider whether you want to create a symmetrical pattern or a more dynamic, staggered arrangement. Measure the wall area and the panels to ensure they’ll fit as planned. Mark out the placement of each panel with a pencil or chalk, beginning at the bottom center of the wall and working outward. This helps maintain balance and symmetry, especially on large surfaces.

Step 3: Apply the Sika 118 Extreme Grab Adhesive

Now that you’ve prepared the surface and planned your layout, it’s time to apply the Sika 118 Extreme Grab adhesive. This adhesive is known for its exceptional bonding power, making it ideal for both vertical and overhead installations. Follow these steps for best results:

1. Cut the Adhesive Tube: Using a utility knife, cut the tip of the Sika 118 Extreme Grab adhesive tube at a 45-degree angle, creating a small opening. Load the tube into a caulking gun.
2. Apply Adhesive: Apply the adhesive in a zigzag or “S” pattern across the back of the panel, ensuring even distribution. Make sure the adhesive is close to the edges and covers the majority of the panel surface for a secure bond. You can also add a few extra dabs of adhesive in the center for additional support.
3. Quick Working Time: Once the adhesive is applied, you’ll need to work quickly, as the adhesive begins to cure within a short window. Make sure to press the panel against the wall as soon as possible after applying the glue.

Step 4: Mount the Panels

With the adhesive applied, it’s time to mount the panels:

1. Align and Press: Starting at your pre-marked point, press the first panel firmly against the wall. Use a level to ensure it’s perfectly vertical. If necessary, tap the panel lightly with a rubber mallet to make any adjustments.
2. Hold in Place: Sika 118 Extreme Grab provides immediate bonding strength, but for heavier panels, you may want to use spacers or temporary supports to keep the panel in place while the adhesive fully cures.
3. Continue Installing: Work your way outward from the first panel, applying adhesive and mounting panels one by one. Make sure to check each panel’s alignment with a level as you go. If you’re leaving gaps between the panels for design purposes, spacers can help maintain consistent spacing.
4. Cutting Panels: If your layout requires custom panel sizes, use an angle grinder or masonry saw to cut the panels to fit. Always wear protective gear and work in a well-ventilated area when cutting concrete.

Step 5: Finishing Touches

Once all panels are in place, inspect your installation to ensure everything is aligned properly and securely adhered. Wipe off any excess adhesive that may have squeezed out from the edges of the panels before it dries.

Step 6: Let the Adhesive Cure

Although Sika 118 Extreme Grab offers immediate grab strength, it’s important to allow the adhesive to fully cure before applying any weight or pressure to the panels. The curing time can vary based on environmental factors like humidity and temperature, but typically, the adhesive will reach full strength within 24 hours. Avoid placing any heavy objects or stress on the panels during this time.

Step 7: Joint Sealing

Sealing the joints of concrete panels with polyurethane is essential for ensuring long-term durability and performance. Polyurethane sealants offer flexibility and excellent adhesion, allowing them to accommodate the natural expansion and contraction of concrete without cracking or losing their bond. This material is particularly effective in exterior applications, where panels are exposed to weather fluctuations and movement. The sealant forms a waterproof barrier that prevents moisture infiltration, reducing the risk of structural damage and maintaining the integrity of the installation. In addition to its weather-resistant properties, polyurethane also provides a clean, smooth finish to the joints, contributing to both the functionality and aesthetic appeal of the concrete panels.

Tips for a Successful Installation:

• Temperature Considerations: Both Australia and the United States have varied climates, so take temperature into account when installing. In extreme heat or cold, the adhesive may cure more slowly or quickly than expected.
• Weight Distribution: For larger, heavier panels, be sure to mount them over wall studs or other solid substrates to provide extra support.
• Safety First: Always wear protective gloves and goggles when working with concrete panels and cutting tools. Also, ensure that your workspace is well-ventilated.

Conclusion

Installing our concrete wall panels is a straightforward process, whether you're a seasoned professional or taking on a DIY project. With proper surface preparation, the right tools, and the superior bonding strength of Sika 118 Extreme Grab, you can create a stunning, durable finish that enhances any interior or exterior space. By following this guide, you’ll have the confidence to install your concrete panels with precision and achieve long-lasting results.