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This photo shows why it is crucial to visit the job site
before quoting floor preparation. Photo courtesy of Dave Stafford.
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Having spent the first 15 years of my career mostly on the
residential side of the business and the last 14 on the commercial side, I have
often marveled at how different the two sides can be. As chairman of the
Flooring Contractors Association (FCICA), I often suggest to people just
starting out on the commercial side of the business to join our organization
for the educational and networking opportunities. For example, at Surfaces
2008, FCICA’s Dave Stafford is tentatively scheduled to present a seminar
called “Ten Transition Steps to Commercial Business for the Retailer.”
Commercial resilient presents several challenges to the
residential dealer and their installers and one of those challenges is in the
area of substrate preparation. Because the jobs are larger, the time schedule
is often rushed. With a lot more money on the line, there is more pressure on
the installer. Proper training and proper planning can go a long way towards
preventing mistakes. Here are a few do’s and don’ts.
Do make sure concrete slabs are tested; don’t assume an older slab is dry
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| Failure
to sufficiently nail the plywood underlayment on this job caused the floor to
buckle, leading to a complete replacement of the vinyl and the plywood. |
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Every floor covering and adhesive manufacturer mandates
moisture testing. If you have a moisture related failure, there isn’t a
manufacturer anywhere who will cover it under their warranty. The industry
standard, ASTM F 710 Standard Practice for Preparing Concrete Floors to Receive
Resilient Flooring states, “All concrete slabs shall be tested for moisture
regardless of age or grade level.” Note the use of the word “shall” which means
it is mandatory. Old or new, basement to penthouse — they all have to be
tested. The two most common methods are ASTM F 1869 (Calcium Chloride Test) and
ASTM F 2170 (Relative Humidity Probe test).
You’ll notice I did not say YOU have to test it. In fact,
the Floor Covering Industry White Paper Position Statement on Moisture Emission
Testing, which was published in 2001, states “It is therefore our
recommendation that concrete moisture vapor emission testing be performed by
qualified independent agencies.” The advantage of independent testing is that
you know it is done right and the general contractor and the flooring
contractor “each has a vested interest on the testing and/or performance
outcome of the installation.” In other words, they would like to see the
concrete pass the test so the job can move forward and get paid. So, if it can
be done independently that’s a good thing because it takes all that uncertainty
out of the conversation.
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Self-leveling underlayment is a fast way to achieve a
smooth, flat floor. Although it may cost more than trowel-applied patching
compounds, the smoother finish and time savings are often worth the money.
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That being said, testing still falls to the installer in
most cases. If you don’t know how to conduct the test, then I suggest you
learn. The good news is the Institute
of Inspection, Cleaning and Restoration
Certification (IICRC) now offers a two-day “Introduction to Substrate/Subfloor
Inspections” (ISSI) course and certification through its accredited schools.
This course would be time well spent if you are going to do a lot of moisture
testing. It would also prepare you for work as an independent moisture-testing
specialist.
Don’t install resilient flooring in buildings that are not climate controlled
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| By
taking advantage of training opportunities, installers can upgrade their skills
to be able to handle more detailed tasks such as moisture testing and
self-leveling underlayment. |
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The reason flooring and adhesive manufacturers have
temperature guidelines in their recommendations (approximately 70F, +/-10F).
The number of failures caused by installing in a building that is too hot or
too cold is substantial because material can expand and contract from extremes
of temperature and adhesive may not cure properly. If you are being asked to
work in conditions that do not agree with the manufacturer’s guidelines the
word warranty may not be in the conversation.
Do take your time smoothing the substrate; don’t assume “a little patching” suffice
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Failure to install resilient flooring in a climate
controlled space can lead to gapping in the finished floor when the product
expands or contracts due to temperature changes.
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Commercial resilient floors are often installed in brightly
lit areas and are maintained to a high-gloss finish. Because of this, even the
most minor substrate irregularities telegraph through to the new floor. My
father used to joke, “Don’t leave your business card on the floor,” when he talked
about smooth high-gloss flooring materials. New slabs or plywood subfloors
usually need some level of work before a floor goes down. On renovation work,
the preparation can be extensive. Be sure to go out and look at the job before
you quote on floor preparation so that you don’t underbid the job and get in
trouble later.
If the floor is rough, it may need more than just patching
compound to get it smooth. Self-leveling underlayments are growing in
popularity because although there is added cost, a self-leveling job results in
a smoother substrate than any amount of patching or sanding and it saves a lot
of time. “Time is money” often applies to big commercial jobs. If you don’t
know how to use self-leveling products, many manufacturers of these products
offer training classes, often at very little cost to the attendees, other than
travel expenses and your time. I know I said time is money, but taking the time
to learn a skill you can make money on is a good investment.
Do pay attention to details when preparing wood subfloors; don’t skimp on underlayment
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The Relative Humidity Test (ASTM F 2170) has been used in Europe
for more than 25 years, and introduced into the U.S.
in the last five years. Many feel this is the most accurate method for testing
concrete for moisture. Photo courtesy of Tramex.
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I recently inspected a job in a retail-clothing store where
the plywood buckled after the vinyl tile was installed, and found the reason to
be not enough nailing. Proper spacing is called out by plywood manufacturers,
and there are two industry standards that specify the same thing: ASTM F 1482,
Guide for Installation and Preparation of Panel Type Underlayments to Receive
Resilient Flooring and APA Engineered Wood Construction Guide, Form E30,
published by the Engineered Wood Association (APA). Both call for fastener
spacing every 3” on the edges and every 6” in the field. This job had spacing
ranging from 5- to 17-inches, and the floor buckled all over the place. All of
the vinyl had to be ripped up, the plywood re-nailed and new plywood installed
over the top. It was quite a mess and an expensive mistake for the installer.
If you are asked to install underlayment on a commercial
job, make sure the product fits the job. Don’t ever use Lauan or other
inconsistent quality products because they can dent, delaminate, telegraph or
even stain the floor. Use a top quality, hard smooth panel so the floor will
perform under heavy traffic. Although the better products cost more, they come with
a warranty and you can bet that the owner would rather pay a little more for a
floor that has a warranty.
Follow
the nailing pattern, stay away from screws to fasten the underlayment down
(staples work best), and patch the joints as directed by the underlayment
manufacturer. See my column “Tips for Selecting and Installing Plywood
Underlayment” (
FCI, July/August 2007) or any number of
other articles in the
FCI archives for more information
about underlayment selection and installation.
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| The
Calcium Chloride Test (ASTM F 1869) is an accepted method for concrete moisture
testing that has been in use for more than 50 years. |
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The cost of repairing or replacing commercial jobs is much
higher than residential projects. If you are branching out into commercial
work, then it pays to take the time to learn some of these techniques such as
how to do moisture testing and how to use self-leveling underlayment. At the
very least, read some of the many articles that have been published in
FCI
magazine or the other resources listed.
