AirFlex Foam: The Science Behind a Longer-Lasting Floor

Most flooring problems—warping, hollow sounds, raised edges, and lock damage—don’t come from the SPC or wood itself. They come from what lies beneath. At QueensFloor, we’ve seen this repeatedly in real homes. That’s why we developed AirFlex Foam, a solution engineered to eliminate the hidden enemies every floor faces: moisture, pressure imbalance, uneven subfloors, and daily structural stress.

Unlike ordinary PE underlayments, our AirFlex Foam is built on a scientific foundation: high-density closed-cell foam, advanced moisture protection, controlled compression, and multi-directional load distribution. These combined features create a stable, long-lasting flooring system—one that performs where it matters most: the subfloor. Through our installation data and field experience, we’ve proven that true durability always starts below the surface.
 

1. Our AirFlex Foam and Its High-Density Closed-Cell Engineering

At QueensFloor, we engineered AirFlex Foam with a 110kg/m³ closed-cell structure—far denser than typical underlayments in the 20–40kg/m³ range. Density directly affects stability. With a significantly higher density, our foam resists compression, retains thickness, and maintains consistent support for SPC locking systems.

The closed-cell structure also prevents moisture absorption and internal vapor buildup. Each microcell is sealed, allowing AirFlex Foam to stay completely dry even as the concrete slab gradually releases humidity—a common issue in Malaysia’s climate. This is why the 2026 Flooring Moisture-Proof Guide identifies closed-cell foam as the most reliable foundation for long-term durability.
 

2. Why Our AirFlex Foam Withstands Pressure Better

We’ve examined countless failed floors, and almost all of them trace back to one problem: the underlayment collapsing. Once the foam permanently compresses, floorboards begin shifting, pushing excessive stress onto the lock joints. Eventually, the locks crack, loosen, or produce hollow sounds.

We designed AirFlex Foam with a tested 180 KPA compression strength, offering exceptional structural resilience that:

• prevents localized pressure collapse

• keeps the floor stable under heavy furniture

• endures daily foot traffic without deformation

• reduces long-term stress on delicate SPC locking systems

From our installation experience, low-density underlayments often fail within 12–24 months, whereas floors installed with AirFlex Foam maintain their integrity for many years.
 

3. The 0.04mm Moisture Barrier — A Critical Layer Many Homeowners Overlook

Concrete slabs consistently release moisture, regardless of whether a house is new or decades old. Without proper moisture protection, vapor travels into the flooring system and causes swelling, mold, and lock deformation.

To solve this, we integrated a professionally bonded 0.04mm moisture barrier into AirFlex Foam—nearly double or triple the thickness found in budget underlayments. This crucial layer prevents:

• vapor from reaching SPC or wood flooring

• mold growth beneath planks

• long-term swelling or cupping

• structural instability caused by humidity

When homeowners ask us, “Do I really need underlayment for flooring?” our answer is always yes, especially in humid regions where moisture damage is inevitable without proper protection.

4. AirFlex Foam Extends Flooring Lifespan Through Engineering, Not Guesswork

To us at QueensFloor, AirFlex Foam is not simply a better underlayment—it is an engineered flooring enhancement system. Its density, structural stability, moisture control, and acoustic benefits collectively address the main factors that shorten flooring lifespan. By preventing moisture intrusion, supporting lock stability, and maintaining consistent structural balance, it makes floors safer, quieter, and dramatically more durable.

For homeowners who want flooring that truly lasts, AirFlex Foam isn’t an optional addition—it’s the foundation. If you’re unsure whether your home needs it, our QueensFloor team can assess your subfloor condition and moisture levels to determine the best level of protection for long-term performance.