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Seam Peaking on a ENHANCER BACKINGhe manufacturer commissioned this report and it was installed over an asbestos subfloor.THE CARPET FIBER/ ID METHOD: Nylon-Chemical FIBER HUE: Beige Background W/ Red, Green CONSTRUCTION: Tufted Loop YARN STYLE: Level Loop BACK SYSTEM: Conventional Tufted PRIMARY BACKING: High Density Polypropylene SECONDARY BACKING: ENHANCER BACKING™ By Dow THE INSTALLATION LOCATION TYPE: Commercial TYPE OF BUSINESS: Convalescent Hospital DATE INSTALLED: 5/97 - 9/97 METHOD: Direct Glue Down SUBFLOOR: Vinyl Tile AREA INSTALLED: Corridors USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION LITERATURE RECEIVED WITH PURCHASE: Yes NUMBER OF EMPLOYEES 185 TEMPERATURE: 75.8°F - 24.3° C RH 50% VACUUM/FREQUENCY: Upright Nightly ENTRY-MATS? Yes SOIL: None Noticeable HEATING TYPE: Central Force Air Gas COOLING TYPE: Central - Gas CLEANING: Do-It-Yourself METHOD: Spin Pad TYPE OF CHEMICAL: Not Determined DATE LAST CLEANED: Continuous TREATMENTS APPLIED: None Reported REASON FOR COMMISSION To determine the reason for peaked seams. THE REPORT Site Conditions and Geographical Information At the time of the inspection the carpet was in a single story 60,000 square feet building and was occupied by 200 senior residents. This building was approximately 4.5 miles from the Pacific Ocean near Seal Beach or 1.2 miles from the Los Angeles County line.. BACKGROUND INFORMATION MADE TO THE INSPECTOR The carpet was installed as part of a refurbishing plan and was reportedly installed directly over the vinyl tile flooring. The vinyl tile had been down longer than the claimant could remember and was not removed due to concerns that it might contain asbestos. Reportedly, there were no loose tiles. Approximately one third of the carpet installed rested over night in corridors before installation. The rest was installed upon delivery. The adhesive used was HENRYS 251, the Seaming Adhesive was HENRYS 246. According to the installer the seams would begin to peak almost immediately up to 15 minutes after installing. Some corrections were immediately attempted during the installation, but were unsuccessful. Later the seams were re-cut to take pressure off the edge and resealed with contact cement. Some improvement was made, but the results were not satisfactory. An inspection was made by two of HENRYS’ employees. The installer pulled up the carpet and the HENRYS’ employees noted that adhesive and seam sealer had been properly used. At the recommendation the mill, some of the seams were re-cut to remove possible compression and then were resealed with contact cement. At the time of the inspection the dealer had concerns about carpet height difference and thus obtained a sample of the carpet that he felt had aggravated the problem. This said sample is included with this report. DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR The vast majority of the side seams were peaked by a fraction of an inch. The ends of some of these seams were vented up. Approximately a dozen panel widths were measured and were found to be between 11 feet nine inches to 11 feet 10 inches, however panels that measured less than this were still peaked. Furthermore, where repairs had been made there were still differences in pile height. Seams in the length were barely or not noticeable. Probing with an awl showed tuft-bind and the attachment to the floor was strong.. ON-LOCATION FIELD TESTING An inspection lamp was used for closer evaluation and to create shadows. Visibility of the seams could be made to disappear or shadows could be created when the lamp was brought down low. An ultra-violet light was shone to find evidence that seaming adhesive was used on cut edges and indeed seaming adhesive was found. THE ISSUE OF THIS REPORT The issue of this report is: why did the seams peak in the width of the carpet? GUIDELINES FOR EVALUATING THE ISSUE Seam Peaking on direct-glue-down can occur when: 1. the usage is heavy
2. the carpet has problems inherent from manufacturing
3. there has been improper installation of the carpet.
INDUSTRY STANDARDS & DEFINITIONS According to the CRI104-1996, the following is said about site conditions. 5.3 Conditioning Before Installation - The carpet and adhesive shall be conditioned in a heated, dry space at a minimum temperature of 65° F (18° C) and a relative humidity between 10% and 65% for at least 48 hours before installation. According to the CRI104-1996, the following is said about direct-glue down over vinyl tiles. 6.2.5 Resilient Floor Coverings - Carpet should not be glued down directly over existing sheet vinyl, homogeneous or laminated solid vinyl tile, and some rubber flooring products. These materials may contain vinyl plasticizers, which could migrate into the carpet adhesive and loosen the bond. Consult individual manufacturers for specific recommendations. Direct glue-down over vinyl asbestos tile (VAT) and/or vinyl composition tile (VCT) is acceptable as long as it is tightly adhered to the substrate and all waxes, sealers, floor finishes, and other foreign materials have been removed. Note: The installation of a second layer of finish flooring material, including some carpets, can trap moisture, resulting in widespread failure, even over subfloors that had never previously shown any signs of moisture. Appropriate moisture tests should be performed before installing over any existing resilient tile. CAUTION: Some sheet vinyls, resilient tile, and cut-back asphaltic adhesives may contain asbestos. Unless absolutely positive beyond any doubt that the floor is a non-asbestos product, assume it contains asbestos, and treat it in a manner prescribed for a floor containing asbestos. Recommended work practices prohibit sanding, dry scraping, bead-blasting, or mechanically pulverizing resilient flooring, backing, or lining felt. Do not use power devices that create asbestos dust in removing cut-back asphaltic adhesives. Various federal, state, and local government agencies have regulations covering the removal of asbestos containing materials. According to the guidelines for installing ENHANCER BACK CARPET, it said this about trimming in section 3, part A -- Cut Lengths and Loose Lay -- Cut carpet to required lengths, allowing 1.5 to 2 inches turn-up at perimeter walls. Position in area by loose laying lengths allowing 1" to 1.5" overlap of face material along edges to be seamed. Make sure carpet lies flat without ripples or buckles before cutting the seams. If necessary use knee-kicker to pattern. Section C said this Row Cut First Length -- Chick pile lay of carpet and select the first edge for trimming. Use a screw driver or the nose of he cushion back cutter to spread the tufted row for at least 1" from the salvage edge) prior to row cutting. Using a cushion-back cutter with a sharp blade row out the first length. Edges may not be perfectly straight after row cutting. This is a normal condition. Seams over can be aligned with a knee-kicker to compensate for minor owing. Section E said this -- E. Trace Cut Second Length -- With the row cut length positioned along, the chalk line position the second length under the first length allowing 1.5" overlap. Using a cushion back cutter with a sharp blade, trace cut the second length using the first trimmed edge as a guide to from the seam. THE INSPECTOR'S ANALYSIS Since the problem was occurring during installation, usage and maintenance were not being considered. The real issue behind this report is whether there is compression on the width seams creating seam peaking or whether there is an inherent difference in height between the two edges of the carpet. Two questionable problems exist with respect to the installation and do not agree with the CRI104.
1. acclimation 2. glue-down over vinyl 3. ENHANCER backing are all combined, some expansion in the width may be possible. One questionable item that does not agree with the installation instruction furnished by the manufacturer is that many if not most of the panel widths were 11 feet, ten inches, which if the carpet came in 12 foot widths, would only allow for a one inch selvedge on each side. However, the manufacturer’s installation requirement specified a one and a half to two inch selvage which means that panel widths should be between 11 feet eight or nine inches. If it were not for panels less than 11 feet eight inches having pile height differences this could explain the problem. Manufacturing related problem would likely be more inherent in ‘carpet height’ differences rather than dimensional stability. More conclusive answers to this seam peaking problem lie in professional laboratory testing.
CONCLUSION Professional testing would likely indicate that problems exist in the total carpet height. Installation errors have also occurred that can contribute or create the problem. |