The Hidden Cost of MgO Panels: Avoid Risk, Stick to the Most Trusted Path

Magnesium oxide (MgO) panels are often marketed as a time-saving alternative to traditional underlayment solutions. But are they really impacting a project according to manufacturer’s claims?

It’s important to understand the inherent risks that MgO panels can pose on a project, and why USG Levelrock® Brand underlayments offer a more reliable, cost-effective solution for multifamily and commercial construction.

Time and Cost Savings

MgO panels are pitched as a way to speed up construction schedules while reducing the cost of installation. But what is often left out of the conversation is the hidden labor and prep work required both before and after installation.

The key issue here is that MgO panels have seams and fasteners that must be patched, leveled, and prepped before final flooring can be installed. This adds time, labor, and cost that is rarely accounted for in the budget and construction schedule. Comparatively, a Levelrock solution does not require any costly patching or extensive prep work to achieve a level subfloor.

Subfloor Leveling

MgO subfloor systems are a panelized solution, which requires near-perfect framing to achieve a level floor. Any deviation can result in uneven surfaces that can compromise flooring performance. This is especially true in luxury vinyl tile flooring, which easily telegraphs any imperfections or screw heads, and can lead to costly rework.

The secret to smooth floors starts with a smooth foundation. The self-leveling application of Levelrock poured gypsum underlayments reduces the need for extra time and labor to achieve a naturally smooth and flat surface. This completely bypasses the need for framing precision with little room for error, ensuring the subfloor is ready to accept the final flooring with less effort.

Moisture Resistance

While MgO panels are claimed to be moisture-resistant, they are not immune to long-term exposure. “Weeping” (efflorescence), swelling, and degradation have been reported, especially in humid conditions. And because these panels are hygroscopic, they naturally draw in more moisture than comparable materials.

On the other hand, Levelrock underlayments have proven dimensional stability under normal conditions, with no risk of the efflorescence prevalent in MgO panels, which leads to the corrosion of metal framing and fasteners.

Fire and Sound Performance

MgO panels claim fire and acoustic benefits, but approved third-party testing is limited. Additionally, the screws used to attach MgO panels create noise flanking paths, leading to more sound transmission between floors.

In stark contrast, Levelrock solutions are included in hundreds of UL-listed assemblies while being acoustically validated by independent labs. What’s more, a poured Levelrock gypsum underlayment in combination with a SAM-N™ or SAM-CSD™ Sound Attenuation Mat effectively decouples the flooring from the subfloor, offering acute acoustic control over impact sounds, such as footsteps, in floor-ceiling assemblies.

For a USG subfloor solution, each of these factors contribute to reliable STC/IIC performance and seamless integration into fire-rated systems.

Installation Complexity and Health Risks

From both mechanical and adhesive fastening to corrosion-resistant screws and intensive patching and skimming at every joint and screw hole, the process of installing MgO panels is labor intensive, to say the least. What’s more, MgO panels that are cut for field modifications can produce harmful dust if inhaled.

With a Levelrock solution, simply pour the material into place, and trade traffic can resume the following day without the need to patch or sand for a level finish. This leads to more optimized sequencing of trades on the jobsite to keep timelines intact and removes the potential for breathing in dust hazards.

The USG Solution

Levelrock comes backed by extensive success in the field with millions of square feet installed and a 10-year limited warranty with the use of a USG and Shaw Industries system, all backed by USG’s comprehensive and trusted technical support.

MgO panel manufacturers make bold claims, promising speed and savings, but USG is well equipped to deliver real-world performance, reliability, and peace of mind. So, choose confidence, not compromise, and avoid risk with a Levelrock solution for your next project.

Explore how USG can support your next project with:

• Faster installation (up to 20,000 sq. ft. per day)
• Superior acoustics and fire performance
• Nationwide availability and support

Reach out to your local USG Levelrock representative and get started today!

Source(s)

1.      Doggett, M.S. & Davis, J.B. (2024). Magnesium Oxide Panels: Emergence of a Modern Building Material. White Paper. Built Environments, Inc.
https://built-environments.com/wp-content/uploads/2024/04/Magnesium-Oxide-Panels-Emergence-of-a-Modern-Building-Material_032524-3.pdf