Malbastone: Single-Panel Fire-Rated Structural Sheathing for Wood Frame Construction

Wood framing dominates residential construction because it's affordable and easy to work with, but wood's vulnerabilities create costly complications. With requirements for fire resistance, sound control, and structural performance, architects and project teams often need to layer multiple materials: plywood subflooring, acoustical mats, poured gypsum concrete, and more. Each layer introduces complexity, coordination challenges, extended schedules, and compounding costs. 

Malbastone eliminates this multi-layer approach by consolidating fire resistance, structural strength, and sound control into a single low-carbon, noncombustible panel. Malbastone can surpass building code and owner requirements with a single layer that saves time, saves money, and lowers environmental impact. Let’s dive into what makes this solution remarkable:

Single-Panel Solution: Multiple Performance Attributes

Malbastone's magnesium oxide panels achieve what traditionally requires multiple layers in a single 1/2" thick, 4'x8' panel. The panels provide listed fire-rated assemblies, acoustical performance with STC and IIC ratings, and structural properties for walls and floors—all while remaining noncombustible per ASTM E136. 

Key performance characteristics:

• Noncombustible construction with listed fire-rated assemblies
• Structural sheathing for wood-frame walls and floors
• STC and IIC rated acoustical assemblies
• Compatible with standard framing tools
• 64% carbon footprint reduction

Replacing Traditional Materials and Methods

Wood-frame walls increasingly require fire resistance. Conventional solutions layer fiberglass panels over plywood, doubling costs and coordination. Malbastone provides both structural sheathing and fire resistance in one panel with nail-holding capacity for direct cladding attachment. The panels eliminate redundant layers and can be engineered into shear wall systems. Framers install Malbastone using familiar tools and construction continues immediately without weather delays or trade stoppages.

Traditional multifamily floors require engineered wood subfloor, acoustical mat, and poured gypsum concrete—introducing moisture and stopping all trades for 7-14 days while drying completes. Specialized contractors must be scheduled separately. Malbastone installs directly over joists as structural subfloor and fire-rated, sound-controlled assembly. In multifamily projects, the product reduces material and labor costs while eliminating drying delays.

Low-Carbon Manufacturing for Sustainable Building

Malbastone's magnesium oxide panels use approximately 50% less manufacturing energy than Portland cement products. The panels' chemistry enables advanced carbon mineralization where up to 20% of panel weight consists of absorbed atmospheric CO₂, creating potential pathways to carbon-neutral production.

Environmental performance highlights:

• 50% lower manufacturing energy than cement products
• Advanced carbon mineralization captures atmospheric CO₂
• Potential carbon-neutral production pathway
• Lighter weight reduces transportation impacts

This carbon profile aligns with codes like California's AB2446, mandating 40% building material carbon reductions by 2035. Architects specifying Malbastone can reduce embodied carbon impacts while simplifying construction and lowering costs.

Connecting with Malbastone Through Acelab's Material Hub

Acelab's Material Hub provides access to Malbastone's technical specifications, fire-rated assembly details, and installation guidelines. Compare Malbastone's single-panel approach against multi-layer systems, review multifamily case studies, and access ICC-ES evaluation reports and Intertek listings. In Material Hub, you can also connect with Malbastone's technical team for project-specific consultation on assembly design and construction detailing.

For more information about Malbastone, explore their products and connect directly with reps in Material Hub.