The Armstrong Woodhaven Ceiling Planks are a popular solution for homeowners seeking to transform outdated or unsightly ceilings—such as popcorn or damaged drywall—into aesthetically pleasing, warm, and modern finishes. These planks are designed for residential indoor use and are available in multiple finish options, including painted white and other wood-look variations. The system is engineered to be installed using a floating ceiling method, allowing for natural expansion and contraction due to humidity changes. This article provides a detailed, step-by-step overview of the installation process, based on the official installation instructions, user experiences, and technical specifications provided by Armstrong and third-party reports.
Understanding the Woodhaven Ceiling System
Woodhaven Ceiling Planks are manufactured as tongue-and-groove, medium-density fiberboard (MDF) planks, pre-finished and ready for installation without the need for staining or painting. The planks are 5 inches wide, 84 inches long, and 3/8 inches thick, with each box containing 10 planks covering approximately 29 square feet. The system supports three primary installation methods, though the most commonly used in residential applications is the Easy Up Installation System, which involves metal tracks, metal clips, and a floating ceiling approach.
Key Features of the System
- Floating Ceiling Design: The system allows for natural movement due to humidity and temperature changes, eliminating the need for direct attachment to walls, trim, or ceiling edges.
- Pre-Finished Planks: No additional staining or painting is required, saving time and labor.
- Compatibility: The planks are designed to be installed over drywall, plaster, joists, or even existing drop ceiling grids.
- Humidity Resistance: The planks are rated for standard humidity levels and should not be used in high-moisture environments such as bathrooms or kitchens.
- Sound Absorption and Fire Rating: The planks have a Noise Reduction Coefficient (NRC) and are fire-rated as Class C, making them suitable for indoor residential use.
The installation process is outlined in the official Armstrong installation manual, and many users have found additional guidance through online videos, such as the Ron Hazelton video and the Armstrong website’s instructional materials.
Pre-Installation Considerations
Before beginning the installation, several key considerations must be addressed to ensure the project proceeds smoothly and the final result is both aesthetically pleasing and structurally sound.
1. Humidity and Acclimation
According to the manufacturer's instructions, it is essential to allow the planks to acclimate to the room’s humidity for 2–3 days before installation. This ensures that the planks expand or contract to their equilibrium state, minimizing warping or cracking after installation. Consistent humidity levels should be maintained in the room post-installation as well.
2. Room Level and Surface Preparation
The ceiling must be level to ensure the planks lie flat and align properly. A long level and chalk line are recommended for marking the layout and ensuring the metal tracks are installed evenly. Any obstructions such as light fixtures, ceiling fans, or vents must be accounted for during the planning phase. If the ceiling is textured (e.g., popcorn ceiling), it is advised to locate the ceiling joists accurately. In some cases, drilling small pilot holes may be necessary to confirm joist locations.
3. Expansion Joints
The system must not span more than 21 feet without an expansion joint (cove). This is to accommodate natural movement and prevent buckling or warping. Users are advised to plan the layout accordingly, especially in larger rooms or open spaces.
4. Material Requirements
The following tools and materials are typically required for a successful installation:
- Armstrong Woodhaven Ceiling Planks
- Metal Tracks and Clips (Easy Up System)
- Wood Screws (2.5-inch)
- Circular Saw, Miter Saw, Jig Saw
- Drill and Drill Bit
- Long Level, Chalk Line, Stud Finder
- Tape Measure, Pencil, Dust Mask, Safety Glasses
- Wood Shims, Painter’s Tape, Rubber Mallet
- Crown Molding, Nails, Hammer, Nail Punch
- Spackle and Sandpaper for Finishing
- Optional: Scrap Cardboard for Template Use
Each box of Woodhaven planks includes 55 clips with screws, which are generally sufficient for the installation, though users should account for extra clips if the layout is complex or includes multiple ceiling penetrations.
Step-by-Step Installation Process
Step 1: Measure the Room and Calculate Materials
Begin by measuring the total square footage of the ceiling to determine how many boxes of planks and clips are needed. Each box covers approximately 29 square feet. For larger rooms or multiple rooms, it is advisable to order an additional 5–10% to account for waste or cutting errors.
Step 2: Install Metal Tracks
The Easy Up system requires the installation of metal tracks along the ceiling joists. The tracks are attached using 2.5-inch wood screws. Users have found it helpful to use scrap wood spacers (cut to the joist spacing) to maintain even spacing between tracks. This is especially useful when working alone, as it allows for consistent parallel placement without constant measuring.
Tracks should be installed perpendicular to the direction of the ceiling joists. Once the tracks are in place, clips are attached to them. Some users install 3–4 clips per track at a time to streamline the process.
Step 3: Install Clips and Planks
After the tracks and clips are in place, the planks are inserted into the clips. The planks are designed with a tongue-and-groove system, allowing them to interlock without the need for nails or screws at the edges. The first plank is inserted into the clips, and subsequent planks are connected by sliding the tongue into the groove of the previous plank and securing the clip to the new plank.
It is important to avoid using planks that are less than 26 inches in length to ensure they are attached with at least two clips. This helps maintain stability and prevents the planks from shifting during installation or after completion.
Step 4: Cutting and Fitting
Cutting is necessary around light fixtures, ceiling fans, vents, and other obstructions. A miter saw or circular saw is suitable for straight cuts, while a jigsaw is recommended for irregular shapes. Some users found it helpful to use the cardboard from the plank boxes to create templates for complex shapes or corners. When reinstalling fixtures after installation, longer screws may be required.
Crown molding is often installed around the perimeter of the room to provide a finished look. The crown molding is attached with finishing nails and caulked or spackled to cover nail holes. It is important to note that the planks should not be attached directly to the crown molding or walls.
Step 5: Final Adjustments and Finishing
After all planks are installed, any remaining gaps or inconsistencies should be adjusted by sliding the planks or using wood shims. A rubber mallet may be used to gently tap the planks into place. Once satisfied with the layout, the crown molding is installed and painted to match the ceiling or room decor.
Common Installation Tips and Considerations
- Use Two Ladders: Many users found that having two ladders significantly improves efficiency and reduces the need to constantly move up and down.
- Stagger Seams: For a more natural and visually appealing appearance, seams should be staggered across rows. This can help minimize the visibility of seams and reduce waste.
- Avoid Direct Attachment: The planks should not be nailed or screwed directly to the walls or trim. The floating system allows for natural movement, and direct attachment could lead to buckling or warping.
- Work with Multiple Cartons: To ensure a consistent appearance, it is recommended to mix planks from multiple cartons during installation.
- Plan for Expansion Joints: If the ceiling spans more than 21 feet, an expansion joint must be included to accommodate movement.
Troubleshooting Common Issues
Despite the relative ease of installation, some challenges may arise during the process. Below are some common issues and solutions based on user reports and official documentation.
1. Difficulty Locating Joists
If the ceiling has a popcorn texture or is otherwise difficult to scan with a stud finder, it may be necessary to drill small holes to confirm joist locations. Once the layout is confirmed, spacers can be used to maintain consistent track placement.
2. Plank Movement or Gaps
If the planks are not sliding freely within their clips or gaps appear between them, it may indicate that the ceiling is not level or that the planks have not acclimated properly. Adjusting the clips or rechecking the level can help resolve this.
3. Cutting Around Obstructions
Cutting planks around light fixtures or ceiling fans can be time-consuming and requires precision. Using templates made from scrap cardboard and a jig saw can make this process easier and more accurate.
4. Crown Molding Joints
Cutting and fitting crown molding joints at corners can be a challenge. Many users recommend using a miter saw for 45-degree angles and applying caulk or spackle to cover any gaps after installation.
Conclusion
The Armstrong Woodhaven Ceiling Plank system is a versatile and user-friendly solution for transforming outdated or damaged ceilings into stylish, modern finishes. With proper preparation, the installation process is manageable for DIY enthusiasts and professionals alike. The floating system design ensures stability and natural movement, while the pre-finished planks eliminate the need for additional staining or painting. By following the step-by-step instructions and heeding the manufacturer's recommendations, users can achieve a clean, polished ceiling that enhances the overall aesthetic of their home.
This guide has been compiled using only the information provided in the source documentation, including official installation instructions and verified user experiences. For those looking to undertake a similar project, the key takeaways include proper planning, accurate measurements, and adherence to the manufacturer's guidelines to ensure a successful and long-lasting installation.