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THE CLAIM STATISTICS
PROBLEM REPORTED: Bubbles & Seams
PROBLEM FOUND: Installations Errors
THE CARPET
MANUFACTURER: Harbinger Industries
443 Nathaniel Drive
East Dublin, GA 31027
1-800-553-6045
STYLE NAME & NUMBER: Timber Lake TMB-801
COLOR NAME & NUMBER: Birch 801
FIBER/ ID METHOD: Nylon-According To Manufacturer
FIBER HUE: Tan
CONSTRUCTION: Axminster
YARN STYLE: Cut & Loop
SQUARE YARDAGE: 715
BACK SYSTEM: Smooth Back
PRIMARY BACKING: Polypropylene
THE INSTALLATION
TYPE LOCATION: Commercial
TYPE OF BUSINESS: Management Consultants
DATE INSTALLED: Conference room & Hallways
METHOD: Double Glue Down
CUSHION: 1/4-Inch Rubber
SUBFLOOR: Concrete Slab
AREA INSTALLED: Conference Room and Hallways
USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION
LITERATURE RECEIVED WITH PURCHASE: Not Determined
TEMPERATURE: 72°F - 22.2° C RH 45%
VACUUM/FREQUENCY: Professional Service Nightly
ENTRY-MATS: In the Downstairs Lobby
SOIL: None Noticed
HEATING TYPE: Not Determined
COOLING TYPE: Not Determined
CLEANING: Spin Pad
DATE LAST CLEANED: Not Reported
REASON FOR COMMISSION
Assess the problem reported and make a determination of responsible parties.
THE REPORT
Site Conditions and Geographical Information
The carpet was installed on the second and third floor of this three-story building
located in the Los Angeles Basin. The condition and maintenance of the property was very
good.
BACKGROUND INFORMATION MADE TO THE INSPECTOR
The carpet was replaced as part of a time management replacement plan. Selection of the
carpet was based upon the color matching the adjoining carpet. The double stick method was
selected in consideration of the pile heights matching the adjoining carpet.
Problems with pattern match were noted immediately after the installation and were not
fixed to the claimant's and commissioner's satisfaction. Eight or nine months later, seams
became unsightly and bubbles formed. Repairs were made using the relief cut method, but
the results added more unsightly seams.
the dealer reports that the adhesive used was DEP/DURABOUND LE8000 and the cushion was
DURAFIT, 80 ounce. Carpet in this installation was transported in a small elevator that
caused a fold mark in the center of the roll. The history of rolling was unknown as per
phone conversation that took place on January 11, 1999.
DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR
In the conference, room measuring 35 feet four inches in width and 50 feet long and three
panels of carpet were installed running the length of the room. The alleged fold mark
formed a deep depressions that ran between seams. A one-inch wide fill-in piece was
inserted in the second seam and gaps were noted in this seam.
The pattern of the carpet made lines running the width of the carpet from ridges and rows
with texture and hue differences. The distance between ridges was approximately ½ inch.
The pattern mismatch was noted between the first seams as noted in the photographs.
Upon adjusting the vertical blinds, lines and bubbles could easily be primarily seen on
the center panel. Probing the bubbles with an awl indicated that the carpet had come loose
from the cushion. Probing elsewhere did not indicate that the carpet had come loose from
the cushion or cushion from the subfloor.
The carpet was pulled back in a corner of this room and the amount of adhesive on the
backside of the carpet was approximately 40 percent as seen in the photograph. Ridges from
the trowel appeared to have dried before carpet was laid. Trowel size appeared to be 'U'
shape at 1/8" x 1/16" x 1/8".
In the second floor carpet, width was measured at 11 feet four inches, but there was a
seam noted making two panels running the length of the hall and additional seams were
noted running the width of the hallway too. Upon closer inspection, the seams were found
to be relief cuts.
ON-LOCATION FIELD TESTING
An ultra-violet light was shone on the seams. Weft and warp yarns of the carpet had a
reflection, but no seam adhesive was found. Where the carpet had been pulled up, adhesive
had an ultraviolet reflection that made the lack of adhesive easier to see as noted in the
photographs.
Numerous moisture tests were performed using a Delmhorst Moisture Sensor. The results of
these tests showed no moisture readings.
THE ISSUES
The questions that I have been asked to address are:
1. What is the cause of the bubbles and loose carpet next to the cushion?
2. Are the carpet seams in compliance with industry standards?
3. Is the alignment of the pattern within acceptable standards in the conference room?
4. Were the cuts made in repairs of the hallway appropriate?
GUIDELINES FOR EVALUATING THE ISSUES
CRI is The Carpet and Rug Institute of Dalton, Georgia. It is a national trade association
representing the carpet and rug industry. Their membership makes-up 95% of all the carpet
made in the United States. Their publications include standards. The CRI104-1996 is the
applicable standard at the time of this installation.
Manufacturer's specifications for Double-Stick installation for this carpet are available
from Mohawk Industries who has two woven divisions; Harbinger and Karastan. Just one
specification is written for both divisions.
Adhesive manufacturer's also publish specifications sheet of which text from both company
mention above are given. Upon request, copies are available for either or both companies.
Bubbles and loose carpet next to the cushion can be supported from the specifications
mentioned above and other sources as being from:
1. Improper usage and maintenance
2. Defects in the cushion or the adhesive
3. Problems inherent in the manufacturing of the carpet
4. Improper installation from:
- Trowel notch size
- Wrong adhesive
- Improper open time
- Improper rolling
INDUSTRY STANDARDS & DEFINITIONS
According to the CRI104-1996, it says this about the double glue-down method:
9.4 Adhesives and Trowel Notch Sizes - For the application of cushion to floor and carpet
to cushion, select the appropriate adhesive and trowel notch size recommended by the
manufacturers of the carpet, cushion, and adhesive. If recommendations are not available,
refer to the general minimum guidelines in Table IV. For proper adhesion of carpet to
cushion, an important consideration in the selection of the trowel notch size is the
texture of the carpet backing. It is important that the trowel notch be large enough to
apply a continuous film of adhesive for 100% transfer into the backing while maintaining
full coverage of the cushion. Woven and unitary-backed carpet require full penetration of
the adhesive into the valleys or depressions between tuft rows.
9.4.1 The adhesive shall be spread uniformly over the cushion surface with the specified
trowel. After sufficient open time, the carpet is to be pressed into the adhesive and
rolled with the appropriate roller. Proper open time considerations are critical for a
successful installation.
9.5 Seaming - A variety of seaming options exist. Consult cushion and carpet manufacturers
for specific recommendations.
9.6 Rolling - Rolling shall be performed with the lightest roller that will achieve 100%
transfer of the floor adhesive into the carpet back. Refer to manufacturer's
recommendation for roller weight.
9.6.1 Jute or Synthetic Secondary Backing - Tufted carpet with jute or synthetic secondary
backing should be pressed into the adhesive bed using a section of carpet core or a
roller. Roll in both directions, but do not over roll.
9.6.2 Unitary and Woven - Unitary carpet and woven carpet must be rolled a second time
about 3 to 12 hours after initial rolling to make sure a strong bond is established.
Specifications for Double-Stick installation for MOHAWK INDUSTRIES say this about
installing the carpet:
8. INSTALLING CARPET
Cut carpet to the necessary length and lay into proper position. Trim selvage using best
method. Follow yarn row on tufted and woven products when possible. When trimming seam, so
not allow knife to penetrate through the cushion. This could cause loss of adhesive. Fold
carpet three (3) feet on each side of seam and apply NU-Broadlok II adhesive using a
1/8" x 1/16" x 1/8" U-Notch trowel. Spread rate should be 6 to 7 square
yards per gallon. Allow the adhesive to set, using proper open time before placing carpet
into the adhesive. Open time depends on the amount of humidity in the area. Higher
humidity requires longer open time. Squirrel cage caret fans may be used to help the
adhesive set faster. Rule of thumb: Nu-Boradlok II adhesive will usually change color
slightly from green to yellow/gold when the moisture begins to leave the adhesive. A good
double stick pad will not absorb adhesive and will require more open time for adhesive to
become tacky. Turn air conditioner on in summer or heat in winter to reduce humidity to
below 65% INSTALLING CARPET BEFORE ADHESIVE HAS REACHED A "TACKY" STAGE WILL
RESULT IN INSTALLATION FAILURE. After sufficient open time fold and push side of carpet
into adhesive. Apply edge sealer to the side of the carpet backing material. Fold and push
next side against first. Roll carpet into the adhesive with a 35-50 lb. roller in both
widthwise and lengthwise directions to attain a good transfer of adhesive to the back of
carpeting.
11. PATTERN MATCH
Karastan Bigelow does NOT guarantee pattern match on any pattern carpet installed using
the double-stick method.
According to specification sheet from NU BROADDLOK PREMIUM PUS, the carpet manufacturer's
recommendation for adhesive, the open time is from 10-30 minutes depending on subfloor
porosity, relative humidity, temperature, and air circulation.
According to DAP INC. makers of the LE 8000, the adhesive that was reportedly used, the
open time is 30 - 35 minutes (depending on temperature and humidity).
THE INSPECTOR'S ANALYSIS
The Double Stick Installation Method has been very popular in the past few years and it is
continuing to be installed in numerous facilities. However, some manufacturers have
discontinued or limited their warranties when this method is used. Problems similar to the
one noted in this inspection can have one or several causes. Evaluations can require
uninstalling and reinstalling section of carpet and have laboratory tests performed on
various components of the installation. Analyses from the guidelines from the issue of
this report of this carpet's problems are as follows:
Bubbles and Loose Carpet Next To the Cushion
Usage and Maintenance
1. In cases where maintenance is a problem, moisture with high alkalinity has been the
cause of similar bubbles and loose carpet. In this case, the DRY ABSORPTION METHOD is
known for its low moisture, fast drying, and low residual residue and moisture test would
seem to verify this. Furthermore, moisture has to be known to come from the concrete
through vapor emissions. Vapor emission testing would confirm how much a factor vapors
emissions there is and of all of the test methods, Calcium chloride (ASTM guidelines)
would give the best results, but once again, there was no suspicion of moisture having
anything to do with the bubbles or loose carpet.
2. There was nothing unusual about the way the carpet was being used such as heavy rolling
traffic or unusual footwear. Moreover, as this is a conference room, it receives less
traffic than the offices used continuously throughout the workweek.
CUSHION OR THE ADHESIVE
1. From Adhesive - Failure when using the carpet manufacturer's brand recommendation has
occurred due to mistakes made by the maker of the adhesive. Testing is often required to
prove responsibility, but there are no signs that this is a likely factor.
2. From Cushion - If volatile organic compounds in the cushion are not compatible with the
adhesive, then plasticizer migration could cause the adhesive to turn to powder, creating
a failure between the cushion and carpet. A professional opinion is that the cushion meets
standards and it is not a consideration for causing these problems.
From Manufacturing - When manufacturing has been a problem, carpets have grown forming
ridges in the length. Laboratory testing for dimensional stability of these carpets
reveals that the problem lies with the fact that there are no official standards. However,
this problem is more often seen on tufted products and bubbles not ridges were seen.
From Installation - Installation errors or failure to comply with the manufacturer's
specification and/or failure to comply with the CRI104 can also create the problems
reported. Only a partial transference of the adhesive to the carpet backing has occurred
instead of the 100% transfer requirement. Evaluations of the particular causes of these
problems are as follows.
1. The trowel notch size was appropriate in all areas that were inspected. Failure to
replace the worn trowel is a common problem in most glue down installation. Further
lifting of the carpet would be necessary to determine if this problem occurred elsewhere,
but is not recommended.
2. Failure to use the adhesive recommended by the manufacturer can cause bubbles or the
lack to transfer to the carpet backing. However, open times are similar between the two
products, and more research, and possible testing would have to be done to determined if
this is an issue.
3. 'Open time' is the window of opportunity in which an adhesive will work and as such,
there is a starting and ending period. The CRI104 and Mohawk Carpet Specifications place
emphasis on this subject. Furthermore, it is noted that laying the carpet too soon will
result in an installation failure. However, when adhesive dries before the carpet is laid,
100% transference of adhesive has not been achieved. A tattle sign of this is when the
definition of the ridges are distinct as if the carpet never flattened them. This problem
has been seen in the areas where the carpet has been lifted as noted in the photographs.
Thus, the carpet was most likely not laid quick enough. A judgement from the bubbles that
can be seen in the conference room would indicate that this problem could be fixed with
relief cuts and/or needle injections of adhesive. However, the view from underneath the
carpet indicates that the problem is more wide spread.
4. Whereas this is a woven product, rolling the carpet twice is required by CRI104,
reference section 9.6.2. It too could lead to the bubbles and separation of the carpet
from the cushion. A major part of knowing whether this was done or not would depend upon
the background information that has not been furnished at the time of the writing of this
report. However, it would be a mute point since one or the other would be the likely
problem.
Seams and Industry Standards:
Seam sealer is required in other types of carpet construction, the CRI104 refers to the
manufacturer when it comes to woven carpet and it is clear that Mohawk Industries requires
it. Some manufacturers on the other hand require hand sewing, but it is clear that whether
carpets are tufted or woven, the edge requires some type of securing in order to improve
performance and appearance. Whereas not every seam in this installation was inspected,
many in the conference room clearly have not been properly sealed as seen in the
photographs. Furthermore, most seams in the entire installation were readily noticeable.
Corrections for this problem in light of the double stick method are often cost
prohibitive.
Pattern Match in the Conference Room:
Section 9.3 of the CRI104-1996 says, "allow for pattern repeat," whereas MOHAWK
INDUSTRIES through its Karastan Bigelow division says in writing that they do "NOT
guarantee pattern match on any pattern carpet installed using the double-stick
method". Thus this is an example of where limitations in warranties with the double
stick method. Whereas specifics on tolerances are not given in writing, nearly all carpets
has some variances in pattern, that installers can overcome with more time spent towards
alignment. However, with double stick installations, considerations have to be made to the
open time of the adhesive, thus pattern match is more difficult. Where professional
opinion might vary, the skills of the installer's technician along with other factors such
as humidity determine the amount of alignment.
Cuts Made In Repairs:
The relief cuts are typical of the ones made to inject adhesive between the cushion and
carpet. Whereas, this is an acceptable method of fixing bubbling, the correction would be
greatly reduced or eliminated if the carpet had been properly attached to the cushion.
CONCLUSION
1. Bubbles and loose carpet in the carpet in question were due to installation error and
are the installer's responsibility.
2. Seams in the carpet in question do not comply with industry standards and are the
installer's responsibility.
3. Alignment of the pattern has no standards and is subject to arbitration.
4. Relief cuts were appropriate for the type of repairs made.
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