commercial broadloom

A proper installation depends on the proper site conditions. The following conditions must be maintained for 24 hours prior to, during and permanently after installation:

• HVAC System: Must be operational maintaining the following conditions.
• Temperature: The installation site, carpet and adhesive must be between 65°F and 95°F. The adhesive will not function properly when applied over an extremely cold surface. Do not begin the installation if the subfloor temperature is below 50°F.
• Humidity: The installation site’s ambient relative humidity must not exceed 65%.
• Moisture: Refer to adhesive manufacturer's guidelines for moisture limits for installation.
• pH: Conduct pH testing on the floor in several locations. A reading below 5.0 or above 9.0 (ASTM F-710) requires corrective measures.

Do not begin the installation if an unacceptable moisture level is detected. Contact Shaw Technical Support for additional recommendations. If excessive moisture is present, the general contractor or building owner must be advised and a decision made if the installation is to begin. Shaw Industries will not be responsible for any moisture related installation failures if these guidelines are not strictly followed.

Concrete Subfloors: Concrete Subfloors: New and existing concrete subfloors should meet the guidelines of the latest edition of ACI 302.   

Wood Subfloors: Wood subfloors must be structurally sound and conform to guidelines of ASTM F 1482 and in compliance with local building codes. 

Wood Subfloors must be Wood Association Approved and primed with a latex primer such as 9050.

• All substrates must be structurally sound, clean, dry, and flat prior to installation. Surfaces must be free of contaminants including, but not limited to: dust, dirt, oil, grease, paint, curing compounds, concrete sealers, adhesive residues*, loosely bonded toppings, and any other materials or conditions that may inhibit proper adhesion. 

• Substrate flatness must conform to the following tolerances: 

• Maximum deviation of 1/8” over 6 feet (3.2 mm over 1.8 m) 

• Maximum deviation of 3/16” over 10 feet (4.8 mm over 3.0 m) 

• Self-leveling or Patching Compounds: Ensure compliance with Technical Data Sheet (TDS) for substrate preparation and priming prior to application of self-leveling underlayment or patching compounds. 

• Fill depressions or cracks with a cementitious patching / leveling compound that meet or exceed Shaw Industries maximum moisture level and pH requirements. Use of gypsum-based patching and/or leveling compounds which contain Portland or high alumina cement and meet or exceed the compressive strength of 3,000 psi (20684 kPa) are acceptable.   

• Dormant cracks wider than 1/32” (0.8 mm), repair with Prepworx CJR400 prior to flooring installation.

• For cracks and saw cuts exceeding 1” (25.4 mm) in depth, use Prepworx MRS101.  

• Moisture Mitigation: For new or existing concrete substrates exhibiting moisture levels that exceed the limits specified for products and/or adhesives, reference either of the two systems below for mitigation. 

• Totalworx Moisture Control Solution 

• Totalworx Vapor Barrier Solution 
   

• Trench Moisture Mitigation: For newly poured concrete trenches (e.g., plumbing), apply a two-part epoxy moisture barrier such as PrepWorx MCS310 to prevent moisture-related flooring failures. Ensure substrate preparation aligns with Shaw’s installation standards. 
   

• Use Prepworx CJR400 at the interface between new and existing concrete. 
   

• Extend Prepworx MCS310 coverage across the trench and a minimum of 8 inches (203 mm) onto the adjacent slab. 
   

• Do not install flooring over substrates that have been chemically abated: Chemically treated surfaces may compromise adhesion and affect flooring performance. 
   

• Curing compounds: (DO NOT USE). If present, they can interfere with the bond of the adhesive to the concrete. Seek assistance from the substrate manufacturer if curing agents are detected.  
   

• Silicate-Treated Concrete: Applies to concrete containing an integrally added (admixed) silicate or cured concrete that has received a topically applied silicate treatment. 
   

• Silicate-Treated Concrete: Confirm the silicate was (Mixed - Integrally Added Silicates) or (Applied - Topically Applied Silicates) in strict accordance with the manufacturer's written recommendations. For topically treated concrete, the slab must be fully cured, and the silicate must have been applied, neutralized, and allowed to dry sufficiently per those recommendations. In all cases, any issues on the project relating to or stemming from moisture remain the exclusive responsibility of the silicate manufacturer. 
   

• Silicate-Treated Concrete Options: 
   

• Option 1: VL201 and QL202, prime with QBC300 (whether the concrete is absorbent or non-absorbent), then install the product. 
   

• Option 2: Install MRS101 at a minimum thickness of 1/8” directly over porous or non-porous concrete without primer, or apply QBC300 primer first and then install MRS101at a minimum 1/8” thickness. 
   

• Sweeping Compounds: Green sweeping compounds can be used but must be swept and removed immediately.   
   

• For dusting / powdering / porous concrete / lightweight concrete prime with a latex primer such as 9050. 
   

• If installed over existing resilient flooring (one layer only), all tiles must be secure to the subfloor. Strip any wax from the surface.

• Raised Access Flooring panels must be smooth, level, secure and free of any material that will affect the adhesive bond.  Carpet tiles must be installed offset from access panel seams.  Gaps between panels must not exceed 1/16” or (1.6mm).

*Refer to Prepare Existing Adhesive section which also includes information specific to EcoLogix/EcoWorx M.

Radiant Heated Floors 

• The heating systems components must have a minimum of 1/2" separation from the   flooring product.  The system must be on and operational for at least 2 weeks prior to installation to reduce residual moisture. Three days prior to installation lower the temperature to 65 degrees, after installation gradually increase the temperature in increments of 5° F to avoid overheating.  Maximum operating temperature should never exceed 85°F. Use of an in-floor temperature sensor is recommended to avoid overheating. Contact the manufacturer of your radiant heating system for  further recommendations. 
   

• Electric Radiant Floors: consist of electric cables (or) mats of electrically conductive materials mounted on  the subfloor  below the floor covering.  Mesh systems are typically embedded in thin- set.  When embedding the system components, use cementitious patching and leveling compounds that meet or exceed Shaw’s maximum moisture level and pH requirements.  Use of gypsum-based patching and/or leveling compounds which contain Portland or high alumina cement and meet or exceed the compressive strength of 3,000 psi are acceptable. 
   

• Hydronic Radiant Floors: pump heated water from a boiler through tubing laid in a pattern under the flooring. Typically installed in channels under a wooden subfloor  (or)  imbedded in concrete slabs.  Requires the installer follow a specific nailing pattern to avoid penetration of the heat system. 

• Pre-existing adhesive ridges must be reduced to a smooth, level, well-bonded residue.
• If you are unsure of the type of preexisting adhesive or active cutback adhesive, use an encapsulation product such as BC9000.
• For multi-purpose adhesive, after reduction of ridges, thoroughly sweep and vacuum any remaining debris.
• For pressure sensitive adhesive, after reduction of ridges, eliminate the adhesive tack with a product such as BC9000.
• Do not use adhesive removers; they affect the bond and the new adhesive being applied.

• Use a multi-purpose adhesive such as 1000 Broadloom.
• For excessive moisture, use 1000 Broadloom (10 lbs/95% RH) 3800 Indoor Outdoor (12 lbs/99% RH)

Apply the adhesive with a 1/8" X 1/8" X 1/8" "U" notch trowel that will give a spread rate of 8 to 10 square yards per gallon or 32 to 40 square yards per 4-gallon pail (based on prime subfloor conditions). On extremely porous or rough floors with residual multi-purpose adhesive, more adhesive will be needed. Spread rate should never exceed 40 square yards per 4 gallons or an installation failure may occur. This indicates a worn or improperly notched trowel. Coverages shown are for estimating purposes only. Actual jobsite coverage may vary according to skill of the installer, porosity/texture of the subfloor or type/angle of trowel used.

The adhesive must have adequate open time to become very tacky prior to installation. The open time will vary depending on temperature and humidity at the job site. The adhesive is ready for carpet installation when the entire ridge of glue becomes tacky. Check by firmly placing a finger into the adhesive and lifting slowly. The glue should have legs or strings and not be wet at the floor surface to ensure a full transfer of adhesive. Fans or air movers will reduce required open time. Inadequate adhesive application will result in bubbles and/or peaked seams and repair will require more time and effort than proper initial installation.

Dry lay the entire area to be carpeted. Prior to cutting any textured, graphic product, implement roll sequencing. This will minimize the normal variations encountered when pattern matching and any bow, skew or pattern elongation between the rolls. Sequence numbers are provided on the bill of lading and invoice; they are located after the dye lot number. If this information is not available, the date and time is backstamped (in military time) on the carpet to assist in sequencing.

Trim the seam edges with tools and techniques best suited for carpet. Trim edges far enough into the material, normally about 8 to 10 rows, to maintain the structural integrity of the carpet. The cutting technique for this backing system is row cut both edges. (Exception – Unitary-backed products are cut using the row cut/trace cut method.) Broadloom products containing a white marker yarn on one side of the salvage approximately 1” from the salvage edge should be removed first. The opposite side should then be cut in order to achieve proper pattern match. Correct pattern matching, gaps and overlaid areas with use of a knee kicker, power stretcher, mini stretcher, stay nails or deadman.A “deadman” is constructed by nailing tack strip completely on one side of a 2”x12”x 4’ long piece of lumber.

Patterned carpets must be cut by the row cut/row cut method and dry laid to ensure pattern match; also check for side match and any visual defects. Use a screwdriver or row runner to separate rows of yarn and cut with a cushion back or loop pile cutter. After the adhesive has become tacky, place the first breadth into the adhesive and apply seam sealer, following with the second breadth pattern matching if necessary. Use a power stretcher, mini stretcher, stay nails or deadman to obtain proper match. Remove stay nails after the adhesive sets up approximately 12 to 24 hours after installation.

Cross seams can be made the same as side seams if the rows can be run across the width. If not, straight edge from the face on the side with the pile lay toward the seam. Run the cushion back cutter along the straight edge with the blade retracted to achievebetter seam quality. This will preserve more yarn by pushing it out of the way. This cut edge is then used as a guide to trace cut the second side of the seam.

All commercial broadloom products require the use of a latex seam sealer such as 4000. Seam sealer must be applied to the edges trimmed for seaming, and cover the thickness of both the primary and secondary backing without contaminating the face yarn.

CAUTION: Seam edges must be sealed to prevent edge ravel, tuft loss, and delamination of the secondary backing in the seamed area.

Roll the carpet in both directions with a 75 to 100 lb. roller to assure transfer of the adhesive between floor and carpet backing.

Where carpet meets other floor coverings, the edges must be adequately protected with an appropriate transition molding or strip that covers the carpet edge at least ½”.

• Place plywood over the carpet when heavy objects are moved.
• Use protective chair mats under chairs with casters. This will prevent excessive wear to the face of the carpet.
• Place a non-staining building material paper over the carpet to protect it when additional construction activity is to take place. Do not use plastic sheeting as it will trap moisture.