Challenges of Resilient Flooring - Constant...
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ChallengesofResilientFlooring−MoistureManagement&Flatness
CrisBierschank,MAPEIFridayOctober21,2016
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ProgramOverview
• FlooringCoveringalwaysstartswithgoodsurfacepreparationtominimizetheeffectsoftelegraphingensuringtheresilientfloorisplaceonaflatsurfacewithout'high'or'low'spotsthatcantelegraphthroughtothefinishedsurface.
• Itisimportanttorememberthat'SurfacePreparation'(moisturemitigation,self-levelingand/orpatching)isnolongeranoption,butitshouldbethe'standard'forallinstallations."
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ResilientFlooring–evidenceofsurfacepreparationissues
Evidenceofpossiblemoisture&flatness(telegraphing)issues
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•Siteevaluation•Compressedsoil•Largeaggregate(capillarybreak)•Smalleraggregate
•Moisturevaporretarder-FirstLineofDefenseAgainstMoistureMigration
•ASTME1745-09definesthreeclassesofvaporretarders:•ClassAvaporretarderwillbemoreresistanttotearingandpuncturingthanaClassBorC•0.1permsasthemaximumwatervaporpermeance forallthreeclassesofvaporretarders•Thicknessesofvaporretarderscanbefrom10mils(0.010inch)to15mils(0.015inch)
•ExteriorDrainageandLandscapingconcerns
10milsto15mils
VaporRetarder
ConcreteonSlab–siteevaluationundertheslab
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NewSlabVs.
OldSlab
TheInstaller: ”I'mnotworriedaboutanymoisturevaportransmissionissueswheninstallingmyfloorcovering…theslabis20yearsold!”
•ASTMF710–11“StandardPracticeforPreparingConcreteFloorstoReceiveResilientFlooring” – “Thispracticecoverstheprocedurefordeterminingtheacceptabilityofconcretefloorsfortheinstallationofresilientflooring.Italsoincludessuggestionsforensuringthattheconstructedconcretefloorisacceptableforsuchinstallationsbutdoesnotcovertestsforadequacyoftheconcretefloortoperformstructuralrequirements.Apermanent,effectivemoisturevaporretarder,ofthespecifiedthickness andpermeance,isrequiredunderallon- orbelow-gradeconcretefloors.Concretefloorsforresilientflooringsshouldbepermanentlydry,clean,smooth,structurallysound,andfreeofsubstancesthatmaypreventadhesivebonding…”.
ConcreteonSlab–OldslabVs.Newslab
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•Excessivemoisturenearfoundation•Brokenirrigationpipes•Interiorplumbingruptures•Pondsorpoolingofwater
•Soilerosionexposingthefoundation
•ClimaticChanges•Rainyseason•Flooding•Saturatedsoil
•Longdryperiods•Soilshrinks,cracks
•Snowandfreezingconditions,thawingofsoil•MoisturepercolatesupintheSpring
•Poorgrading,slopetobuilding, waterrun-off
Irrigation&Roots
SoilErosion
WaterPooling
WaterPooling
ExtremeClimaticChanges
ConcreteonSlab–conditionsmayhavechangedin20years!
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• Allsubstratesmustmeetthefloorcoveringmanufacturer’sspecifications– MoistureEmissionRates
• Typically<3-5lbs/1000sqft/24hoursor85%RH
– Smooth,flatanddefectfree• Typically¼”-10’
– FollowResilientManufacturerforbothmoisturerequirements&floorflatness
• Substratetocomplywithindustrystandards(suchasASTMF710).– CompressionStrengths>4000
psi– TensileStrengths>175psi
SubfloorRequirements–thehand-offtotheinstaller
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ExampleTheamountofmoisture/waterthatcantypicallybeextractedfromaslabevery7daysbasedon: MVER=to20lbs./1,000sq.
ft.(9,07kgper92,9m2)/24hrs
17gallonsofwater
CanbeaCostlyGamble:Reputation,Time,&Money!
Wait&SeeMethodof‘MoistureManagement’
MVERinConcreteSlab–Quantifyingthemoisture
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Impuritiesbroughttothesurfaceoftheconcrete,causingchemicalreactionsthatformstainsthattransferthroughthesheetgoodstothewearsurface
• Delaysinfloorinstallation• Higheralkalinity• Extendeddrytimeforwaterbasedadhesives• Limitationsofflooringmanufacturerrecommendations
<5lbs,<3lbs
Stainingonthesurface
oftheFloorCovering
MVT–whatcanhappenunderyourfloorcovering
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• ResilientIndustryhasunderstoodforyearstheimportanceofaddressingtelegraphing
• Aflatsubstratemakesallofthelayersaboveiteasiertoinstallcorrectly
• FinishedCoverings:carpet,vinyl,rubbertiles/flooring,wood,porcelaintile&stone
• Floorprepdoneproperlycontributestogettingtheneededfoor adhesiveormortartransfertotheproductduringinstalls.
• Adhesivetransferisreducedorseverelycompromised
FloorFlatness–Acceptablesubstrateforfinishedcovering
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HowFlatisflat? – ACI• Specificationstypicallyincludea“Floorflatness”requirement(anda“Floorlevelness”requirement)
• Thehigherthenumber,theflatterthefloor
FF Maxdrop/10ft TypicallyConsidered
20 Conventional
25 1/4" ModeratelyFlat
35 Flat
45 VeryFlat
50 1/8"
60 SuperFlat
100 1/16"
ThereisnodirectcrossoverbetweenFFnumbersto‘1/4”in10’typeofterminology,buthereisageneralguideline:
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F-NumberMeasurements-Division3/Concrete
• Pointelevationsmeasuredatregular12in.(300mm)intervalsalongeachline.
• Measurementlinesdistributeduniformlyacrosstherestsection.
• Minimumnumberofreadingsrequiredforstatisticalapproach.
• Measurementlinesnotwithin2ft (0.6m)ofanyslabboundary,constructionjoint,isolationjoint,block-out,penetration,orothersimilardiscontinuity.
• Flatnessmeasuredwithin72hrs.ofconcreteplacement.
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Curlmovement⎯lifting&relaxingofslab• Whyitisimportanttoconsider‘slabcurl’wheninstallingaResilientfloorcovering?• Sinceduringthe ‘curing’ processtheconcreteslabisexperiencingboth‘tensile’and‘compressive’forces
causingtheslabto‘lift’andthen‘relax’.• Duringthiscuringcyclewheretheslabisshrinkingduetothe‘waterofconvenience’evaporatingoffofthe
slabsurface—asitliftsandrelaxestheresultissurfacecrackingandcreatingelevatedorunevenareas.• Inordertomeetslabflatnessthecontractorgrindstheslab,theslabrelaxesfurtherleavingtheareasthat
weregrounddownlowerthentherestoftheslab. TheinstallerwillbethefirstpersonnotifiedtomakeanynecessaryrepairstoensureanacceptablesubstrateforinstallationoftheResilientfloorcovering.
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Methodstoaddressflatness:• Mudbed/screed• PatchingCompounds
• Cement-based&gypsum-based• Self-levelers
• Cement-based&gypsum-based
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PatchingCompounds• Concretesubstrateswith
small,localizedareasthatarenotflatcanbeaddressedwiththistechnique
• Highspotsaregrounddownwithadiamond-bladedrotarygrinder
• Lowspots(“bird-baths”)arebuiltupwithapatchingcompoundappropriatetothesubstrate
• Thewholeareamaybecappedwithathinlayertrowel-appliedpatchtomakeituniform
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Self-Levelers⎯Overview• Self-Levelersareproducts
designedtoflowfreely,developahighcompressivestrength,andflattensubstratesthathaveunevenareas.
• Self-Levelersareverycommoninresilientandwoodflooringinstallationsandastileformatsgrowinsize,anecessitytohaveinatileinstaller’stoolboxaswell
• LevelerspreparethesubstratetoreceiveflooringbyflatteningittoaFFofbetween50- 80
FF Maxdrop TypicallyConsidered20 Conventional25 1/4" ModeratelyFlat35 Flat45 VeryFlat50 1/8"60 SuperFlat80100 1/16"
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Self-leveler⎯Advantages?
• Floorsthatrequiresignificantcorrection
• Concrete• Levelingonetypeofsubfloortomeetanother
• Floorsthatcanhandletheweight
• Overradiantheatingsystems
• Largeareas• Timeiscritical
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Self-levelers⎯Variousformulations/Tasks
• Cement-based,flowablelevelers• Gypsum-basedlevelers• Rapid-settinglevelers• Lightweightlevelers(typicallyfeatheredgeto½”)
• Levelersforverythincaps• Reducedsurfacepreplevelers• Moistureresistantlevelers
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Self-levelers⎯Cement-based• General-purpose,costeffective• Upto1”thick• Cementcureswhenmixedwithwater• Canlaysheetgoods14-16hoursthenextday
• Requireaprimer• Requiresomesurfacepreparation(generallyshotblastingorgrinding)
• Barrelmixorpumpable• Createasmooth,flatsurface
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• Upto2”thick• Withanappropriateprimer,doesnotrequiremechanicalsurfaceprofiling
• Goodchoiceoverexistingtile,VCT,orpreparedcutbackandcarpetresidues(withappropriateprimer)
• Nextdayinstallationofmembranesorsheetgoods
• Barrelmixorpumpable• Smooth,absorbentsurface
Self-levelers⎯Cement-based/reducedsurfaceprep
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• Moreexpensive• Upto2”thick• Acceleratedsettime• Accessforothertradesinaslittleas1-3hours
• Membrane/Sheetgoodsinstallationnextday• Requireaprimer• Barrelmixorpumpable• Createasmooth,flatsurface
Self-levelers⎯rapid-setting
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• Moreexpensive• Upto1”thick• Foruseinunenclosedbuildings(Core&
Shell)• Priortospaceacclimationwithout
HVACsystemcontrollingoccupiedspace
• NotforEXTERIORapplications• Canbeusedover‘green’concrete(7days)
withapprovedprimer• Nextdayinstallationofmembranes/Sheet
Goods• Barrelmixorpumpable• Smoothsurface
Self-levelers⎯moistureresistant
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• Cost-effective• Fire-ratedproperties• Upto3”thick• Drybyevaporation(thickness,
temperature,andhumidityconsiderations)• Unlikecement-basedthat
drybyhydration• Requireaprimer• Goodforuseoverexisting
gypsumsubstrates(multi-family)• Barrelmixorpumpable• Createasmooth,flatsurface• SLU&Patchingcompounds• Ettringite risk:whencement-
basedpatchisusedovergypsum,separatewithaprimerlayer
Self-levelers⎯gypsum-based
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• Theleveleryouchoosedeterminestherequiredprofile.Mostwillreference“CSP”numbersdevelopedbytheConcreteRepairInstitutethatshowhowroughthesurfacemustbe.
• Profilingopensupthesubstratetobondwithtoppingandincreasestheabilityofthetoppingtowithstandimpactforces.
• Sealers,oil,paint,waxesandothercontaminantsshouldberemoved
• Mechanicalremovalispreferredtoreducethelikelihoodofintroducingnewcontaminants
Self-levelers⎯mechanicalprofiling
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• Primer,doesitreallymatterwhichoneIuse?• Yes,primersimproveadhesion,bond
strengthandreducesurfacedefects(pinholes)inthefinishedsurface.
• Whenselectingaprimerthefollowingfactorsmustbeconsidered:1. Typeofsubstrate—porousandnon-porous
concrete,gypsum-based,plywood,existingtile,adhesiveresidue.
2. The‘serviceconditions’thatthetoppingorunderlaymentwillbeexposedtoduringits‘servicelife’,fromawarehousetoresidentialflooring.
3. Primerscanrangeinchemicalmake-upfromwater-basedacrylictotwo-component100%solidsepoxyandareformulatedforvarioussubstratesandporosities—tomatchtheprimertothespecificapplication.
Self-levelers⎯primers
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Self-Leveling⎯Barrel Installation• Smallerareasarepoured
frombuckets• Largerareascanbepumped• Alwayspourintoa‘wetedge’
sothepourscanbeworkedtogether
• Onceyoustart,finishtheentirearea
• ‘Porcupine’rollersbreakthesurfacetensionoftheleveler
• Spikebottomshoesallowinstallertowalk‘over’theinstallation
• Gaugerakesworklevelertotheproperdepth
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• Mixingistypicallydonetwoorthreebagsatatimeinabarrelmixerinordertobepoured,allthewayupthroughmultiplebagsmixedtobepumpedcontinuously.
• Don’toverwater!• Themostcommonissuewithleveler
installationsistoomuchwater• Whenpumpingitiskeytoensurethe
watertomixratiostaysconstant• Leadstosoft,powderysurface,color
variations,anduncontrolledshrinkage
Self-Leveling⎯Pump Installation
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SurfacePreparation⎯MoistureIssues/Patching/Self-Leveling
• Manyresilientcallbacks1.)moisture2.)telegraphing• SurfacePreparationisnolongeranoption,butshouldbethe‘standard’
• Siteassessment…vaporretarder?MVERexceedingflooring/adhesivemanufacurerrecommendations?
• Understandingthe‘degree’offlatnessrequiredforthe‘finishedcovering’.ie:CarpetVs. 5’x10’largeformatthinporcelaintile
• Screed,patchingcompounds,SLUs• Self-levelerscansavetimeandmoney• Typeofsubstrate,environmentalconditions,andtimingoftheinstallationdeterminewhichlevelertouse(cementitiousorgypsum)
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THANKYOUQUESTIONS?
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