Rebond foam. A material that does more than fill a space Rebond foam. A material that does more than fill a space

Rebond foam. A material that does more than fill a space

Its dense structure and carefully controlled density help reduce the transmission of sound, impact energy, and vibration. Discover a material selected to suit a specific location and purpose.

Flexible foam transformed into a dense, engineered material

The process begins with flexible polyurethane foam offcuts generated during production. The foam is shredded, bonded with a polyurethane binder and then formed under pressure to achieve a specified density.

This transforms small pieces of foam into a cohesive, porous and resilient structure. Rebond foam can be manufactured in a range of densities, thicknesses and formats, allowing the same technology to be used in everything from thin underlays to panels and thicker technical layers.

Three properties that set rebond foam apart

Mass

Mass

The higher the density of rebond foam, the more material it contains within the same volume. At a given thickness, this also increases its mass per unit area—an important factor in solutions designed to reduce sound transmission through building elements.

Resilience

Resilience

Rebond foam is not a rigid board. Under load, it can deform and dissipate some of the energy generated by impacts and vibrations. This allows a suitably selected variant to act as a resilient layer between rigid structural elements.

Cohesive structure

Cohesive structure

The material does not have a loose, fibrous structure. It is compressed to a specified density and then cut into panels, mats or rolls. It can be cut to size and fitted to the structure. Once installed, it remains concealed beneath the floor or behind the finished lining.

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Floor

Floor

Footsteps and impacts cause the floor and structural slab to vibrate. A rebond foam underlay acts as a resilient layer between the hard subfloor and the floor finish.

It helps reduce the transfer of impact energy to other parts of the structure. The right option should be selected based on the type of flooring, available build-up height, installation method and expected loads.

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Wall

Wall

Loud conversations, television, and music are primary sources of airborne sound. Within a wall assembly, rebond foam works together with the lining boards, frame, and other layers of the partition.

Wall Barrier is fixed directly to an existing wall and concealed behind a lining. Wall Panel is installed within a frame built in front of an existing wall or inside the structure of a new partition.

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Ceiling

The void above a suspended ceiling does not have to remain empty. A suitably selected rebond foam product is installed within the frame and concealed above the lining boards.

As part of the complete ceiling assembly, the material helps reduce the transmission of sound energy and vibration between the ceiling components, lining boards and structural slab above the room.

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What sets rebond foam apart?

No single material is best suited to every purpose. Mineral wool, thin foam underlays, cork, rubber and rebond foam differ in their structure, mass and performance.

Rebond foam is worth considering when a solution needs to combine mass, resilience and a cohesive structure, with a density selected to suit the specific application.

Mineral wool

Mineral wool has a fibrous structure and is widely used to fill cavities in building assemblies. Its key advantages include thermal and acoustic performance, as well as the availability of products with specific reaction-to-fire classifications.

Rebond foam has a more cohesive structure and can be manufactured at higher densities. It introduces a different combination of mass and resilience into the assembly. Depending on the construction, the two materials may serve different purposes and, in some solutions, can also complement one another.

PE and XPS underlays

Thin PE or XPS underlays are lightweight, widely available and help keep the floor build-up to a minimum. Their performance, however, depends on each product’s specific structure, thickness and intended use.

Kokon Floor underlays use rebond foam with a controlled density of 120 kg/m³. This provides greater mass within a thin layer than typical lightweight foams, while allowing the material to retain its resilience.

Cork

Cork is a natural material, selected in part for its structure and thermal properties. It can be a good solution where the natural origin of the material is one of the main priorities.

Rebond foam, meanwhile, can be manufactured in a range of densities, thicknesses and formats. This allows the material to be tailored to different parts of an assembly, from a thin underlay to a thicker infill panel.

Rubber mats

Rubber can provide high mass and mechanical durability, which is why it is often used in solutions exposed to heavy loads, impacts and vibration.

Rebond foam offers a different balance of mass, resilience and ease of cutting. The choice between these materials should be based on the expected loads, installation location and required performance of the complete assembly.

Decorative acoustic foams

Visible panels and profiled acoustic foams are primarily used to reduce reverberation within a room. They can improve listening and recording conditions, but they are not the same as a material concealed within a building element.

Rebond foam installed beneath a floor, within a wall or above a ceiling works as part of the building assembly. Its purpose is not to decorate the room, but to support a solution designed to reduce the transmission of sound and vibration.

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Recycling built into the material itself

We live in a world where we consume ever more raw materials, while too much valuable material is left without a further use once a stage of production is complete. That is why we should ask not only how a product performs, but also what it is made from.

Rebond foam uses flexible polyurethane foam production offcuts that cannot be reused in their original form. Once shredded and bonded, they become a dense, engineered material with new properties and further applications.

Choosing rebond foam will not solve every environmental problem. It is, however, a tangible step towards a circular economy: it puts material that has already been produced to further use, rather than relying solely on newly sourced raw materials to create another product. This allows technical performance to go hand in hand with a more responsible approach to resources.