Installation Incorrect Pad1
This report was done for a consumer
Type of Site: Residential
CUSHION: 1/2 Inch Rebond 3 Lb./Sq. Ft.
SUBFLOOR: Tile
AREA INSTALLED: Livingroom/Diningroom, Hallway, & Three
Bedrooms
REASON FOR INSPECTION
This inspector was asked to examine the installation for compliance to standards and practices.
THE REPORT
Geographical Background Information
The carpet was located in the claimant’s free standing house which was in a residential neighborhood. This neighborhood was approximately eight miles east of down-town Los Angeles on the southwestern edge of the San Gabriel Valley. The condition and maintenance of the house and neighborhood was good.
BACKGROUND INFORMATION
The carpet in question was a replacement for an older carpet that had worn-out. This new installation took place over three days and upon completion the claimant was not pleased. Most of the seams were unsightly and a long seam in the living-room appeared to be light on one side and darker on the other. There were also ‘bumps’ in the carpet and missing yarns next to the base-board.
To resolve these problems the dealer performed correction services over March 22 and 23, 1996. Some of the old tackless strip was replaced. The seam in the living-room was moved further away from the natural light source and some improvements were made to the bumps.
The claimant did not feel that the corrections were sufficient to make the carpet acceptable, therefore an inspection was commissioned by the dealer. This report allegedly said that the installation was within industry standards.
Description
THE SEAMS - The seam in the living-room was immediately noticeable and was lighter on the window-side of the room. In the living-room and hallway there were missing yarns that were in the form of gaps. These gaps were located two to three inches from the wall and were less than a half inch in length. Loose and fuzzy yarns were also noticed on other seams near the living-room to the hall intersection. Near this seam the carpet was not attached to the tackless strip and the tackless strip was old and was falling apart.
UNDERNEATH THE CARPET - The carpet was pulled back in the living-room and the inspector noticed that the carpet and cushion seams ran the same direction. In the places where the ‘gaps’ were noticed, the missing yarns were on the back-side of the carpet. It was noted that there was no duct tape used on the cushion seams. A dark line ran down the length of the cushion where the old carpet seam was located. The carpet’s seaming tape was three inches wide. A section of tile was chipped off on the fire place and one of the tiles was loose. In placing the carpet back the inspector noticed that the edge of the carpet extended beyond the perimeter of the wall and the tile area around the fire place.
TESTS
A carpet stretch test was performed. The test involved a professional opinion by the inspector to determine whether a power stretcher was used. The industry standard is drum tight. After pulling the carpet up by the face yarns and letting it pop-back into place, it was determined that the carpet was not drum tight.
A Pile Direction Test was done using a plain piece of paper and an ordinary pencil. The pencil is rolled on the paper while it is laying on the carpet. As it is rolled the paper begins to move. This movement confirms the pile direction of the carpet. The result of this test revealed that the seam ran the same direction.
A sample of the claimant’s cushion was weighed by the inspector to determine the cushion thickness and density. This test consisted of weighing a one foot square of the cushion. The cushion height was divided into one foot and then multiplied by the weight. This test was performed on an electron scale from Acculab, model number: V-333. This device is accurate to .1 grams. The results of this test showed a three pound density of the cushion. The thickness was measured at one half inch.
A carpet awl was used to probe the carpet’s edge to check for seaming adhesive. The result of this test revealed that there was no seaming adhesive used.
THE ISSUE
The question that I have been asked to address is: does the installation of the carpet comply with the industry standards and practices?
GUIDELINES FOR EVALUATING THE ISSUE
Industry Standards used for residential installations are:
the CRI105 by the Carpet and Rug Institute of Dalton Georgia.
the manufacturer’s installation instruction
According the floor covering dictionary knee-kicker tears are defined as:
Knee-Kicker Tears - First of all, it is not recommended that any carpet be installed using a knee-kicker. This tool was designed to aid the installer in positioning the carpet and as a starting tool. When you see knee-kicker tears, they will usually be around the perimeter of the wall. Another damage a knee-kicker will cause is fuzzy areas on the surface due to the installer using the wrong head. All knee-kickers are equipped with a "nap-grip" and long pins. The pins are to be used on cut pile and cut loops. The "nap-grip" is used on all loop piles.
On page six on the CRI 105 -1994 RESIDENTIAL INSTALLATION STANDARDS it says this about seam and a light source:
Seams . . . be sure there is agreement between you and the customer as to the locations of all seams that may be required. before the job starts. Usually, seams are best laid toward the primary natural light source. Visibility of the seams will vary with the type of carpet purchased. Carpet seams cannot be guaranteed to be invisible.
Concerning cushion thickness from the CRI105 on page 13 it says this:
9.1 Select Of Separate Cushion - Contact the carpet manufacturer to obtain cushion requirements in order to prevent problems resulting from improper cushion selection and the possible voiding of applicable warranties. Inappropriate choice of cushion may result in accelerated loss of appearance retention, wrinkling, buckling, and the separation of the carpet backing or seams. Cushion thickness should not exceed 7/16 inch (11 mm)
Concerning carpet cushion on Residential stretch-in-installations the CRI105 says this from page 14:
9.5 Cushion Installed Wall-to-Wall Cushion should be securely fastened to the subfloor with staples or nonflammable cushion adhesive around the perimeter of the installation. Seams shall be secured with staples or nonflammable cushion adhesive. However, tape -- such as duct tape -- shall be used for most seams on rubber cushion. These procedures are used to prevent shifting of the cushion during and after the installation.
Cushion is to be installed in the longest continuous lengths possible. The cushion seams should not be installed directly under the carpet seams. Generally, they should be placed at right angles to the carpet seams. When this is not practical shift the cushion so that seams are at least 6 inches (150 mm) to one side of the carpet seams.
Concerning layout and cutting, the CRI105 says this:
9.8 Edge Securing - Once the edges are trimmed, seam adhesive must be applied to both trimmed edges. Allow the seam adhesive to dry thoroughly before seaming. Improperly sealed edges can lead to seam delamination or loss of face yarns, with unsightly results.
Concerning tapes, the CRI105 says this:
9.10 Hot Melt Tape - A fabric seaming tape precoated with a thermoplastic adhesive is centered beneath the seam. Heat from an electric iron melts the adhesive, laminating the carpet backing to the tape. A grooved iron is recommended for better penetration of the adhesive. Proper iron temperature is essential, with special care taken for carpet with synthetic backing or synthetic pile yarns. Consult tape manufacturer’s recommendation for heat settings. Always run the iron In the direction of the pile. ". A heat shield for the iron Is required. A metal surface should not be used to weight the seam behind the iron, as metal traps the heat. Wood should be used for this purpose.
A premium tape with high tensile strength and sufficient adhesive on the woven scrim is recommended. NOTE: In some critical seaming situations, to minimize elevating and pecking, a 6-inch (150 mm) wide tape should be used.
Pre-stretch the carpet in the seam areas before making the seam.
Concerning power-stretching, the CRI105 says:
9.14 Power Stretching - Following seaming, carpet must be power stretched and firmly hooked onto the tackless strip at the starting walls in surrounding area. The use of a power stretcher is mandatory.
Also in section 9.14 it say this about the use of a wall trimmer:
A wall trimmer shall be used to trim the carpet along walls and abutments. The trimmer must be adjusted to leave sufficient excess carpet to tuck into the gullies.
THE INSPECTOR'S ANALYSIS
The seam problem in the living-room is called a side match and in this case is due to outside light crossing a seam that is slightly peaked. The standards would like for installers to run seams directly into the light source to minimize this problem, however layout of carpet are debatable. Two things are for certain; 1.) a six inch tape should have been used to minimize the peaking and 2.) a plan should have been given to the consumer to show where the seams would be located.
The carpet cushion was not in compliance with industry standards with respect to improper thickness, improper density, improper layout, and non use of duct tape on the seam. The most serious of these problems was the thickness and density. In some cases some fiber producers allow one half inch pad with six pound density pad. However, the HUD minimum density is five pounds per cubit foot. Improper thickness and density is a source for future problems with the latex that holds the carpet together.
The layout of the cushion should be perpendicular to the lay of the carpet, however, there is room for some exceptions according to the CRI105 STANDARDS.
The lack of duct tape is a problem because synthetic cushion can separate with time. This is more of a problem on second floors with wood floors, but it can still happen in an installation of this type. When it does happen the carpet will appear to have a dark line running the length of the gap that is formed when the cushion pulls apart.
The lack of a seaming adhesive is a serious problem because as it is there is already a visible effect on the carpet. The pulled yarn in the hallway seam and the delamination at the carpet’s edge around the fireplace are problems that the use of seaming adhesive would address. Considering the amount of traffic and the style of the carpet unsightly seams will likely be a growing problem in the future.
Power Stretching is a subjective call on the part of an inspector, but in this case the inspector believes there is little room for debate. The carpet was easily detached from the edge of the wall, in fact in one place the carpet was not even attached, and there was still some buckling at the time of the inspection. The lack of power stretching along with the thickness and density problems together can lead to additional buckling and even delamination of the carpet. The standards specified this requirement in bold type, emphasizing the importance of this procedure.
The dark line down the cushion in the living-room has the appearance of an improper heat setting from the iron used to put in the carpet seam. High heat setting on polypropylene carpets also causes some distortion in the seams. Other tests to investigate this are destructive since this would mean undoing the seam, however, the inspector can think of nothing else that would create the strange distortion on the cushion.
The gaps in the carpet fit the so called ‘KNEE-KICKER TEARS’. On tufted cut pile carpet this problem is easily corrected by trimming the yarns that have pulled above the plain. However, on looped pile there is an inherent problem in that the yarn pulls out the carpet or is pushed through to the other side. In this case the yarn was pushed through.
CONCLUSION
The installation in question is not in complacence with the CRI105 RESIDENTIAL STANDARDS with respect to:
cushion thickness
lack of duct tape
cushion layout
seaming adhesive
power stretching
carpet layout
trimming the carpet
replacement of tackless strip