Buckling on a Direct GlueDown
This report was done for a carpet mill and buckling was due to installation error.
THE CARPETFIBER MAKER & NAME: Zeftron® 2000
FIBER/ ID METHOD: Nylon
FIBER HUE: Multi-Colored, Predominantly Black
CONSTRUCTION: Tufted Loop
YARN STYLE: Level Loop
SQUARE YARDAGE: 601.55
BACK SYSTEM: Conventional Tufted
PRIMARY BACKING: Polypropylene
SECONDARY BACKING: Polypropylene
THE INSTALLATION
LOCATION TYPE: Commercial
TYPE OF BUSINESS: Restaurant
METHOD: Double Glue Down
CUSHION: 1/4 Inch
SUBFLOOR: Concrete
AREA INSTALLED: Diningroom, Bar, & Lobby
USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION
LITERATURE RECEIVED WITH PURCHASE: Not Determined
NUMBER OF EMPLOYEES 75
TEMPERATURE: 73.2°F - 22.8° C RH 72%
VACUUM/FREQUENCY: Upright Daily
ENTRY-MATS: Yes
SOIL: Moderately Soiled
HEATING TYPE: Central Force Air Gas
COOLING TYPE: Central - Electric
CLEANING: See Report
REASON FOR COMMISSION
The carpet has seam and wear problems.
THE REPORT
Site Conditions and Geographical Information
The carpet was installed in a free-standing single story building in a retail shopping mall parking lot. This facility was located in the coastal plain of southern Orange County. The condition and maintenance of the property was good.
BACKGROUND INFORMATION MADE TO THE INSPECTOR
The carpet was reportedly the original carpet installed for this restaurant. A few weeks after the installation, ridges began to form. Repairs were made with some improvements, but the problems continued to grow. Afterwards the seams began to open.
The carpet was originally cleaned once every quarter. Since this last year, they have been cleaned only once due to fears it would aggravate the buckling.
DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR
Ridges running perpendicular to the lay of the carpet were noticed in a common walkway that led to the patron’s tables. These ridges were less than one inch in height. Elsewhere, ridges running the length of the carpet were noted. Two or three seams had opened and were frayed at their edges.
On January 7, 1997 this inspector went back with an installer to perform a deeper probe into the carpet. The carpet and attached cushion were pulled back and were later re attached to its original condition. Trowel marks were found in the concrete, but the cushion was not attached to the concrete in many places. No trowel marks were found on the top side of the cushion and the cushion was not attached to the carpet in many places.
ON-LOCATION FIELD TESTING
An ultra-violet light was shone to find evidence that seaming adhesive was used on cut edges. Seaming adhesive was not used as noted in photograph number one.
Numerous moisture tests were performed using a Delmhorst Moisture Sensor. The results of these tests revealed that there were slight moisture readings in the ridges, but there were no readings elsewhere.
Numerous pH tests were taken using a digital type pH meter and a special low moisture probe that made direct contact with the face yarns. This device is accurate to ± 0.1 and was calibrated with a laboratory testing solution immediately before these tests were made. All tests were made using distilled water with a pH of 7.0. The test results were as follows:
random areas 6.1 6.1 6.2 6.0 6.2 Ave. 6.12
The pH of any of the above substances if present at the time of testing would be affected by any other substance with a pH and also by dilution with the distilled-water.
THE ISSUE OF THIS REPORT
The question that I have been asked to address is: what has caused the carpet to buckle?
GUIDELINES FOR EVALUATING THE ISSUE
Buckling can be caused by:
1. errors in installation
2. liquids that are excessively applied or spilled onto the face yarn that get into the carpet backing.
3. errors in manufacturing
TEXT FROM THE CRI104
Concerning ATTACHED CUSHION Carpet, the CRI104 - 1994, says this on pages 13 and 14:
10. ATTACHED CUSHION Carpet with cushion material permanently bonded to the back of the carpet by the manufacturer should be installed as follows:
10.3.4 The correct open time for adhesive is required. The applied adhesive must develop "legs" or tack prior to laying the carpet into the adhesive.
Open time will vary dependent upon environmental conditions.
10.3.5 IMPORTANT: Sufficient adhesive application must provide a 100% coverage of the floor and carpet back when installed.
THE INSPECTOR'S ANALYSIS
No evidence of problems inherent from manufacturing was noted at the time of the inspection and although there was some moisture found in the buckled area, the installation errors were overwhelming.
The likely reason the cushion did not properly attach to the concrete was due to improper open time. Since the trowel marks were intact, the cushion must have been laid after the time that the adhesive was still sticky. Thus no legs were formed.
The reason the cushion did not attach properly to the carpet is not clear. However, the wrong adhesive or improper application would be the likely cause. Both of these cases would be related to installation errors.
CONCLUSION
Buckling in the carpet in question was due to problems inherent in installation, based upon the lack of legs from the cushion to the floor and the cushion to the carpet.