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Delamination From LatexThis inspection was commissioned by the carpet mill and the installers discovered the delamination during the installation.THE CLAIM STATISTICSPROBLEM REPORTED: Delamination SAMPLES FROM INSPECTION: Carpet PERSONS PRESENT: Inspector & Dealer THE CARPET FIBER/ ID METHOD: 90% Polyester, 10% Nylon-According To Manufacturer FIBER HUE: Gray CONSTRUCTION: Tufted Cut Pile YARN STYLE: Saxony Plush SQUARE YARDAGE: 215 BACK SYSTEM: Conventional Tuft PRIMARY BACKING: Polypropylene SECONDARY BACKING: Polypropylene THE INSTALLATION LOCATION TYPE: Residential DATE INSTALLED: 11/97 METHOD: Stretch-In CUSHION: 1/2 Inch Rebond SUBFLOOR: Concrete AREA INSTALLED: See Report USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION LITERATURE RECEIVED WITH PURCHASE: Not Reported TEMPERATURE: 70.9°F - 21.6° C RH 54% ADULTS: 2 - CHILDREN: 3 - PET(S): 0 DO THEY SMOKE? Yes SOIL: Not Applicable HEATING TYPE: Central Force Air Gas COOLING TYPE: Central - Electric CLEANING: None Yet REASON FOR COMMISSION The carpet’s primary and secondary backings have reportedly separated. THE REPORT Site Conditions and Geographical Information The carpet was located in the claimant’s free standing single story house and was partially installed. This house was located in a residential neighborhood on the western edge of Simi Valley and was vacant at the time of the inspection. BACKGROUND INFORMATION MADE TO THE INSPECTOR The carpet was being installed as part of the moving-in process. No problems were noticed until the installers got near the center of the roll and noticed large holes. Seams started to fail and an extra deep selvage was made to keep yarns from pulling loose, however this correction did not resolve the problem. In addition to all this, the dealer reported that the center of the roll felt moist. The claimant was present at the end of the inspection and commented that he was living in a rental house and had to move. He also requested that the carpet problem be resolved quickly so that the house would be ready to move into by Friday. DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR The balance of the roll was noted in the garage and was rolled out. Three holes measuring more that a foot in diameter were noted near the center of the panel. Stress or wrinkles were noted in the secondary backing in close proximity of these holes and location of the holes seem to be such that they were laid on top of each other in the roll. A seam located in the dining-room had been reopened and the primary was easily pulled off the secondary. The family-room located in the front of the house was measured at 12 feet wide. A fill-in piece was noted at 3 1/2 inches from one wall. Yarns in the seam pulled free completely and easily when the seam was brushed. Similar conditions were noticed throughout the installation. The secondary backing was pulled apart easily on the remnants and a heavier than normal amount of powdery residue was noted. There were no unusual odors noticed in the carpet. ON-LOCATION FIELD TESTING The results of Tuftbind Tests performed over a random area on the remaining roll in the garage.: 2.5 7 3 2.5 1.5 2 2.5 1.5 2 2 2 2 2 2 4 Ave 2.57 Numerous moisture tests were performed using a Delmhorst Moisture Sensor. This test would indicate the presence of moisture locked-up in salt compounds from urine and detergents. The results of these tests showed no moisture throughout the installation of the roll. THE ISSUE The question that I have been asked to address is: what has caused the carpet to delaminate? GUIDELINES FOR EVALUATING THE ISSUE 1. Delamination can be caused by: 2. extraordinary foot or mechanical traffic 3. improper cushion thickness or density 4. some topical spills including but not limited to dry, polar solvent that dissolve latex 5. prolonged wetness 6. manufacturing defect in the latex INDUSTRY STANDARDS & DEFINITIONS Standards are available upon request. THE INSPECTOR'S ANALYSIS The carpet has not been down long enough for usage, maintenance, or installation issues and thus are not considered a likely culprits. Also, observations and background information did not support this as culprits. Solvents typically leave distinguishable odor that were not noticed. Prolonged wetness could be a likely candidate, but it is a mystery as to why there were no residual readings. If clean water had evaporated, then the tuft-bond would have likely returned to normal, but the tuft-bind was very weak. Thus problems inherent in manufacturing from the latex seems to be the best reason on why the carpet is delaminating. Supporting this would be the excessive powdering of the latex. CONCLUSION Delamination in the carpet in question was due to problems inherent in manufacturing based upon background in-formation, tuft-bind tests, and observations made. Further latex testing should confirm this. |