XPS500 Dry Underfloor Heating Panel with 1 mm Profiled Aluminium Layer

XPS500 with a 1 mm profiled aluminium layer is a high-strength dry underfloor heating panel designed for efficient floor heating without screed and, in most cases, without additional load-distribution boards.

The panel is made from 500 kPa high-strength XPS, providing excellent compressive strength and allowing various types of final floor coverings to be installed directly on top.

Suitable floor coverings include:

• laminate flooring;

• parquet / engineered wood flooring;

• vinyl flooring / LVT;

• ceramic and porcelain tiles.

Thanks to the high compressive strength of XPS500, under normal operating conditions there is no need to install additional OSB, gypsum fibre, Cetris or other load-distribution boards, provided that the selected floor covering and installation system allow direct installation.

1 mm Profiled Aluminium Layer

One of the key advantages of the XPS500 panel is its 1 mm thick profiled aluminium layer.

Unlike conventional foil-covered dry underfloor heating panels, the aluminium does not cover only the flat upper surface of the XPS. It is also profiled into the pipe grooves and return bends.

Once the heating pipe is inserted, it is surrounded by the aluminium heat-distribution layer inside the groove. This increases the contact area between the pipe and aluminium, allowing heat to be transferred efficiently from the pipe across the entire surface of the panel.

This provides several important benefits:

• increased contact area between the pipe and aluminium;

• improved heat transfer;

• more even distribution of heat across the floor surface;

• fast system response to temperature adjustments.

Textured Aluminium Surface

The profiled aluminium has a textured rather than completely smooth surface.

This surface structure provides improved conditions for mechanical adhesion compared with completely smooth aluminium and is particularly useful when installing bonded floor coverings.

The combination of the high-strength XPS500 core and textured profiled aluminium surface makes the system suitable for both floating and directly bonded floor coverings.

Direct Tile Installation

One of the main advantages of the XPS500 system is the possibility of bonding tiles directly onto the panel, without installing an additional Cetris, gypsum fibre, OSB or other rigid load-distribution board.

This allows you to:

• reduce the overall floor construction height;

• reduce the amount of materials required;

• shorten installation time;

• reduce the thermal resistance of additional layers;

• transfer heat to the final floor covering more efficiently.

Tile adhesive is applied to a clean and properly prepared textured profiled aluminium surface. An adhesive system suitable for this type of construction and for metal/aluminium substrates must be used.

In bathrooms and other wet areas, a suitable waterproofing system must also be installed in accordance with the requirements of the selected floor construction.

Important – Heavy Point Loads

Although XPS500 panels have a very high compressive strength of 500 kPa, it is important to consider not only the total weight of furniture or equipment but also the area over which the load is transferred.

Heavy objects supported by narrow legs or feet can create a significant concentrated load over a very small area of the floor.

Special consideration is required when installing:

• freestanding bathtubs on legs or feet;

• heavy double beds with narrow legs;

• heavy wardrobes or other furniture with small support points;

• heavy household appliances or equipment supported by small feet;

• any other objects that create high concentrated point loads.

In these areas, one of the following two solutions is recommended.

Option 1 – Local Reinforcement at Support Points

If the exact position of the legs or feet of a heavy bathtub, piece of furniture or appliance is known in advance, the XPS layer can be cut out locally and replaced with a rigid support.

Suitable support materials include:

• OSB;

• timber boards;

• plywood;

• another suitable rigid, load-bearing material.

The support must be the same thickness as the XPS layer being removed in order to maintain an even floor construction height.

This allows the concentrated load to be transferred through the rigid support to the structural substrate rather than directly into the XPS.

Before installing local reinforcement, the position of the heating pipes must be carefully checked. Supports and fixing elements must not damage or interfere with the heating pipes.

Option 2 – Load-Distribution Board

If the exact location of heavy furniture or equipment is not known, if there are multiple heavy objects, or if the room layout may be changed in the future, it is recommended to install a rigid load-distribution layer over the entire XPS500 system or over the required area.

Suitable materials include:

• Cetris boards;

• OSB boards;

• gypsum / gypsum fibre boards;

• other suitable rigid floor-grade load-distribution boards.

The rigid layer distributes concentrated loads from furniture legs or equipment over a larger area of the XPS500 panel, reducing the risk of local deformation.

📌 Important: an additional load-distribution layer is not required for normal foot traffic or evenly distributed floor loads. It is recommended where high concentrated loads are applied over a small area.

Quick Installation Guide

1. Subfloor Preparation

XPS500 panels must be installed on an even, stable, clean and dry substrate.

Suitable substrates include:

• concrete;

• OSB;

• timber floors;

• existing stable tiled surfaces;

• other suitable rigid substrates.

If necessary, the panels can be bonded to the substrate using an adhesive suitable for XPS.

2. Laying the Panels

The panels are positioned according to the planned heating pipe layout.

The panel already includes:

• straight pipe channels;

• pipe return / turning zones;

• aluminium-covered pipe grooves.

Therefore, there is no need to form additional heat-distribution channels on site.

3. Installing the Heating Pipe

The heating pipe is pressed directly into the aluminium-lined groove.

The 1 mm profiled aluminium layer is formed inside the pipe groove as well, allowing the pipe to remain in close contact with the heat-distribution aluminium.

This enables efficient heat transfer from the pipe to the aluminium layer and across the heated surface.

4. Final Floor Covering

Laminate flooring – can be installed directly over the system in accordance with the laminate manufacturer's installation requirements.

Parquet / engineered wood flooring – can be installed directly over the system, provided that the flooring and installation method are suitable for underfloor heating.

Vinyl / LVT – thanks to the high strength of the XPS500 substrate, it can be installed directly, subject to the requirements of the specific flooring manufacturer.

Tiles – can be bonded directly to the textured profiled aluminium surface using an adhesive system suitable for this construction.

Where high point loads are expected, local rigid supports or an additional load-distribution layer must be provided before installation of the final floor covering.

Why Choose XPS500?

The compressive strength of XPS500 is 500 kPa, providing an exceptionally strong base for the final floor covering.

Under normal operating conditions, a very simple, low-profile floor construction can be achieved:

structural substrate → XPS500 heating panel → final floor covering.

Fewer layers mean a lower overall floor build-up, simpler installation and lower thermal resistance between the heating pipe and the room.

Key Benefits

• 500 kPa XPS compressive strength.

• 1 mm profiled aluminium layer.

• Aluminium covers both the panel surface and the pipe grooves.

• Pipe return bends are also formed in aluminium.

• Textured aluminium surface.

• Large contact area between the heating pipe and aluminium.

• Efficient and even heat distribution.

• Laminate and parquet can be installed directly.

• Vinyl / LVT can be installed directly.

• Tiles can be bonded directly to the panel.

• Under normal conditions, no additional load-distribution board is required.

• Possibility to install local rigid supports for heavy furniture legs or equipment.

• No screed required.

• Low overall floor construction height.

• Fast installation.

• Suitable for new-build and renovation projects.

Specifications

• Material: XPS – extruded polystyrene.

• Strength class: XPS500.

• Compressive strength: 500 kPa.

• Heat-distribution layer: 1 mm profiled aluminium layer.

• Aluminium surface: textured.

• Pipe grooves: formed within the profiled aluminium layer.

• Return / turning zones: pre-formed in the panel and covered with aluminium.

• Heating system: dry underfloor heating.

• Screed: not required.

• Suitable floor coverings: laminate, parquet / engineered wood, vinyl / LVT, ceramic and porcelain tiles.

• Tile installation: tiles can be bonded directly onto the properly prepared textured aluminium surface.

• High point loads: local rigid supports or an additional load-distribution layer must be used where required.

• Dimensional tolerance: ±1–2 mm.