The Hidden Costs of Poured Concrete Flooring Systems

A Smarter Alternative for Multi-Family and Commercial Floors

For decades, poured gypsum toppings have been a common way to meet code-required fire and sound ratings in multi-family projects. But in today’s fast-paced construction environment, with compressed schedules, high labor demand, and increasing performance requirements, those poured systems often carry hidden costs.

Modern panelized alternatives like M4® Underlayment and NOCOM® Structural Cement Board help developers and contractors build faster, lighter, and with fewer delays while meeting or exceeding performance standards.

Construction Delays

Poured toppings require curing before walls, plumbing, or finishes can proceed. This waiting period can stretch into a week or more, slowing the entire sequence of trades.

Panelized systems install dry. Once in place, framers can immediately move ahead with walls, and mechanical trades can start rough-ins without delay.

Field note: On a recent hotel project, switching to NOCOM Subfloors allowed plumbing rough-ins and bathtub sets to happen weeks earlier than they would have with poured toppings — a small change that had a big ripple effect across other trades.

Added Moisture in the Building

Poured systems introduce significant moisture that must be vented or dried out of the structure, often with additional heating or dehumidification in colder months. That not only adds time but creates conditions where finishes and materials must be carefully managed.

By contrast, M4 Underlayment and NOCOM Subfloors arrive dry, with no added water load to the building.

Structural Weight

Dead load is another hidden factor. Gypsum toppings typically add 9–10 lbs/sf to an assembly.

• M4 Underlayment: ~2.7 lbs/sf

• NOCOM Subfloor: ~4.5 lbs/sf

This significant weight savings eases demand on the buildings structure, logistics and material handling. Not only saving time, but reduces materials and expenses on your job.

Extra Trades and Coordination

Poured toppings require specialized wet trades, equipment, pump trucks, and additional scheduling. Any delay in their sequence can cascade to all the following trades.

M4 and NOCOM are installed by the framing crews already on site, using standard carpentry tools. This simplifies coordination and reduces reliance on additional subcontractors.

Performance Without Extra Layers

Poured toppings are often used to reach sound and fire ratings, but that may require multiple layers of material.

M4 and NOCOM deliver premium performance benchmarks in a single dry layer:

• Fire Resistance: UL Classified 1- and 2-hour assemblies

• Sound Ratings: Proven STC/IIC 55+ with common floor finishes

• Non-combustibility: ASTM E136 and Class A surface burning (ASTM E84)

• Durability: Resistant to impact, corrosion, mold, and freeze-thaw cycles

The Smarter Alternative

Poured systems meet code, but they bring with them hidden schedule, moisture, weight, and coordination impacts that add cost and complexity.

With M4 Underlayment and NOCOM Subfloors, builders eliminate those risks while still achieving certified fire, sound, and structural performance. The result: faster schedules, lighter structures, and simpler builds that stay on track.

• Faster schedules with no curing delays

• No added water in the building

• Lighter assemblies, easier handling

• Certified fire and acoustic performance

• Simplified installation with standard tools