Old habits die hard in construction but change is possible...

The flooring industry is constantly challenged by the same issues - installing products too early, wet concrete, non-flat sub-floors, sub-floor surfaces not prepared, heat not on, windows not in and lack of installer training and certification. In fact, as construction speeds up to meet demands for faster build times, especially with the threat of an increase in the cost of borrowing money lurking in the economic wings, the provision of acceptable conditions for the flooring contractor is becoming even less likely.

This raises the importance of supporting those in the construction team (Building Owner, Construction Manager, Design Authority, Flooring Contractor and Manufacturer) with good, timely information that helps all involved plan ahead for the flooring covering installation. As one of the last significant trades onsite, the flooring contractor needs certain conditions that if not planned for in advance will be next to impossible for the construction manager to provide without extra time and/or extra money…two things in short supply at the end of a build or renovation.

The good news is, there is a generic Canadian floor covering industry reference manual available for specification, which when included in the construction documents means that correct flooring process and supportive language is in place to help the construction team plan for and navigate through the challenges of commercial floor covering installation. 

Here’s a list of some of the types of information you’ll find in the Reference Manual that has been helpful in clarifying a number of recurring issues on site:

1.    Based on national flooring standards, slab moisture testing should be conducted by a third-party testing agency according to ASTM F-1869 or F-2170. Testing is not within the scope of work for the flooring contractor who has no way of controlling the test field from spoilage by other trades. The flooring contractor is however, responsible to verify proper testing has been done and acceptable moisture levels reached prior to installation. According to national standards, the construction manager should provide and pay for third-party testing. For the flooring contractor, installation is deemed to be acceptance of surfaces and conditions. If conditions are found to be unacceptable the Construction Manager must be advised in writing.

2.    Alkalinity testing must be conducted at the same time as concrete moisture testing. High alkalinity present in all new poured concrete can re-emulsify flooring adhesive causing bond failure.

3.    Heat needs to be on well in advance of flooring being shipped to site. Concrete slab temperature needs to be brought up to above 15c for most adhesives and above 10c for many floor leveling products.

4.    Ambient (room) Relative Humidity in the installation area must be maintained at ‘service’ conditions (eventual expected living conditions) - usually between 35 and 55%.

5.    NFCA specifications require that flatness of the sub-floor (waviness) is brought up to 3/16” over 10’ by the Construction Manager. Minor correction beyond this standard is considered part of the floor covering contractors’ normal scope of work. Without this flatness standard the floor covering installation should not start. The manual provides an updated ‘Hydraulic Cement Underlayment’ (section 03 54 15) for use in guiding the application of such toppings or leveling compounds.

It should be understood that Floor Flatness/Floor Level (FF/FL) requirements provided by Division 03 ‘Concrete’ according to ASTM 1155 do not guarantee an acceptable surface for the flooring contractor because this measurement system stops 2’ from walls, construction joints and columns and does not measure through doorways. For this reason, flatness standards of 3/16” over 10’ may have been achieved in the field (middle areas) but not necessarily at the perimeters. For this reason inspection/approval of the sub-floor must take place well in advance of floor covering installation. Additional Hydraulic Cement Underlayment (toppings) added to the parent concrete are not in the scope of work for the flooring contractor. The flooring contractor can however bid on this work as a billable extra.

6.    Sub-floor surfaces should be prepared by the Construction Manager. Curing agents, paints, oils, waxes, old adhesives and other contaminants should be removed prior to the flooring contractor arriving on site. This also is not in the flooring contractors scope of work but can be undertaken as a billable extra.

7.    Non-porous concrete surfaces should be tested for water absorbency according to ASTM F3191…a simple and effective test involving dime-sized droplets of water and a 60 second test time.

8.    A Concrete Surface Profile (CSP) of 2 for Resilient Flooring (and 3 for Hydraulic Cementitious Underlayment) should be provided by the Construction Manager to the Flooring Contractor. Equipment for profiling concrete surfaces (Shot blasting machinery) is effective and readily available. Contact the International Concrete Repair Institute (www.icri.org) for information about samples that show concrete profiles.

9.    Bond (Pull) Tests are an important, simple and effective way to confirm the overall floor system (adhesive, self-leveller, floor covering) are bonded together and to the parent concrete.

Is good enough ok?

Today we have the ability to affect a greater level of positive change. With internet, social media, and repeat messaging of the bigger problem items we can reach a huge audience, create more awareness, a better understanding of the problems and so push for improvement. The NFCA standards for example, are now online at www.floorcoveringreferencemanual.com This is a big step forward for the floor covering industry.

Yes, we are just a finishing trade but unfortunately we’re a finishing trade that brings lasting and deeply problematic issues for all involved when problems arise. Brands are damaged, business relationships broken and good companies end up in court.

When the designer, builder, sub-trade, manufacturer’s rep and project manager (building owner rep) are all aware of what flooring products and installers need to get the job done right (before it’s too late), solutions stand a chance of being implemented. And, if the deadline is ultimately to supersede quality (i.e. early installation is chosen) then the risks will be understood by all going in, and the responsibility won’t fall where it has for too long, the floor guy.

Giving the spec a voice on site!

One last thing on solutions. A third-party inspection service is now available for the commercial flooring sector called the Quality Assurance Program (QAP). Roofing, Paint, Millwork and other trades have all had there own QAP for years, flooring is the latest addition. QAP ensures specifications are read and that items such as those listed above are understood and addressed in advance, this helps to get the installation done right and ultimately leave warranties in place. Once engaged, QAP assigns a certified flooring inspector who will review the project specs, offer unbiased advice and opinion and issue a series of reports at critical stages of the installation. The inspector is concerned with what’s right not who’s right. With this in mind, he/she will hold a flooring specific pre-installation site meeting, check installer qualifications, check that the specified products are onsite and that acceptable conditions are provided. For full NFCA and Quality Assurance Specification Guide go to: https://www.nfca.ca/quality-assurance-specification-guide.html

This is how we secure positive change for all construction parties involved in a floor covering installation. For more information on scheduled education events and inspector certification go to https://www.nfca.ca/education.html