Add a Splash of Imagination DuraCeramic DuraCeramic Dimensions Ovations ® ® Installation and Technical Guide ® SAFETY PRECAUTIONS pre- 1978 homes, child care facilities and schools must be certified and must follow specific work practices to prevent lead contamination. Detailed information on training and certification is available through the EPA at the following web site www.epa.gov/lead/pubs/toolkits.htm. Safety for yourself and others on the job site is your responsibility as a professional flooring installer. Read and observe the following safety precautions. Mold and Mildew Issues • R ead and follow the safety precautions and warnings printed on the label of the installation accessory products being used. Obtain the appropriate MATERIAL SAFETY DATA SHEETS (MSDS) for information that may be required for products which may contain hazardous materials. MSDS are available for the adhesive, joint sealer, and grout. You may obtain an MSDS for these products by calling or writing to your Congoleum distributor or contacting Congoleum at the address or phone number listed on this page. • Wood and concrete: If working on wood or concrete subfloors, use proper safety precautions when sanding or grinding. Avoid creating dust. Concrete and cementitious patching compounds contain crystalline silica, which is a known carcinogen. Wood dust is classified as a nasal carcinogen in humans. Airborne wood dust may also be an explosive hazard. • Resilient Flooring Prior to removing an existing floor following the RFCI Recommended Work Practices for Removal of Resilient Floor Coverings (unless state or local law requires other measures), if there are visible indications of mold or mildew or the presence of a strong musty odor in the area where resilient flooring is to be removed or installed, the source of the problem should be identified and corrected before proceeding with the flooring work. In virtually all situations, if there is a mold issue, there is or has been an excessive moisture issue. Visible signs of mold or mildew (such as discoloration) can indicate the presence of mold or mildew on the subfloor, on the underlayment, on the back of the flooring, and sometimes even on the floor surface. If mold or mildew is discovered during the removal or installation of resilient flooring, all flooring work should stop until the mold or mildew problem (and any related moisture problem) has been addressed. In areas where flooding has occurred, it is recommended that damaged flooring be removed following the RFCI Recommended Work Practices for Removal of Resilient Floor Coverings (unless state or local law requires other measures). Any underlayment and subfloor should be allowed to thoroughly dry and, if necessary, cleaned, disinfected, and otherwise remediated consistent with the U.S. Environmental Protection Agency (EPA) guidelines referenced below. Any structural damage or signs of mold or mildew must be corrected before reinstalling resilient flooring. This may include, for example, replacement of the underlayment and/or subfloor. Warning Do not sand, dry sweep, dry scrape, drill, saw, beadblast, or mechanically chip or pulverize existing resilient flooring, backing, lining felt, asphaltic “cutback” adhesive, or other adhesive. These products may contain asbestos fibers and/or crystalline silica. Avoid creating dust. Inhalation of such dust is a cancer and respiratory tract hazard. Smoking by individuals exposed to asbestos fibers greatly increases the risk of serious bodily harm. Unless positively certain that the product is a non-asbestos containing material, you must presume it contains asbestos. Regulations may require that the material be tested to determine asbestos content and may govern the removal and disposal of material. Whenever possible, existing flooring should be left in place and the new floor installed over the top. If you must remove old flooring material, contact your retailer or Congoleum Corporation, Installation Department, P.O. Box 3127, Mercerville, NJ 08619, for a copy of recommended work practices for the removal of resilient floor coverings. These practices should be followed. For water damage caused by leaking fixtures, the source of the moisture leak must be located and corrected. Any structural damage must be repaired and any signs of mold or residual moisture must be addressed before replacing the resilient flooring in the affected area. To deal with mold and mildew issues, you should refer to the EPA guidelines that address mold and mildew. Depending on the mold and mildew condition present, those remediation options range from clean up measures using gloves and biocide to hiring a professional mold and mildew remediation contractor to address the condition. Remediation measures may require structural repairs such as replacing the underlayment and/ or subfloor contaminated with mold and mildew as a result of prolonged exposure to moisture. NOTICE Various federal, state and local government agencies have regulations covering the removal of in-place asbestos containing material. If you contemplate the removal of a resilient floor covering structure that contains (or is presumed to contain) asbestos, you must review and comply with all applicable regulations. Regulations outside the United States may vary. Copies of the Resilient Floor Covering Institute (RFCI) Recommended Work Practices for the Removal of Resilient Floor Coverings are available from: The EPA mold guidelines are contained in two publications “A Brief Guide To Mold, Moisture and Your Home” (EPA 402-K-02-003) and “Mold Remediation in Schools and Commercial Buildings” (EPA 402-K-01-001). Appendix B of the “Mold Remediation in Schools and Commercial Buildings” publication describes potential health effects from exposure to mold, such as allergic and asthma reactions and irritation to eyes, skin, nose and throat. These publications can be located on EPA’s website at www.epa.gov/iaq/molds/ Resilient Floor Covering Institute 401 East Jefferson Street Suite 102 Rockville, MD 20850 • Keep work areas free of obstructions, such as tools and scrap or loose tiles, and dispose of scrap materials promptly and properly to eliminate a slip or trip hazard. Please note that the RFCI Recommended Work Practices are subject to change as new practices are incorporated. It is your responsibility to determine that the recommended work practices you use are those in effect. • Always use the correct lifting practices. • Use heavy-duty extension cords and keep them in good repair. • If using minerals spirits as suggested in this guide, CAUTION: Minerals spirits is a flammable material. Read and follow cautionary instructions on the labels of these products. Caution: Paints Containing Lead Certain paints may contain lead. Common renovation activities like sanding, cutting, removal of trim and demolition can create hazardous lead dust and chips which can be harmful. Beginning April 22, 2010 contractors performing renovation projects, including preparation of an area to receive floor covering, that disturb lead –based paints in • W ear protective equipment when appropriate such as safety glasses, respirators, NIOSH-designated dust masks, kneepads, gloves, etc. 2 DuraCeramic, DuraCeramic Dimensions and Ovations Residential Recommended for use in all areas of the home except countertops, ceilings and wet areas like shower walls and shower floors. DuraCeramic, DuraCeramic Dimensions and Ovations are constructed with a limestone composite base that is fortified with a polymeric resin. It provides toughness and flexibility to resist breaking from normal subfloor deflection, expansion and contraction. This feature permits fast, easy installation using a pressure sensitive adhesive over a wide variety of subfloor surfaces without extensive preparation. Light Commercial Recommended for areas receiving light commercial foot traffic. DuraCeramic and DuraCeramic Dimensions are not recommended for installation in exterior or unheated areas, wet areas, like shower walls or shower floors, countertops, ceilings, in commercial kitchens or food processing areas or on ramps. For information on other specific applications, contact the Congoleum Installation and Technical Office at (609) 584-3888. OVERVIEW Use Congoleum DS100 DuraSet Adhesive, for all approved floor applications. Set tiles into tacky dry adhesive. Mortar, mastic or other adhesives are not recommended. Depending on the desired appearance, tiles can be installed with or without grout. General Information • A lways store and transport cartons on a flat surface stacked no more than 10 cartons high. Handle tiles and cartons with care. Tiles can be damaged if dropped. • G routed floor tiles are laid with a 1/8” to 1/4” space at the joints depending on the desired grout line width. Congoleum DuraCeramic Premixed Grout can be applied immediately after tile is installed. Do not use cement epoxy or other premix grouts. • Ungrouted floor tiles are laid with no space at the joints. The joints on an ungrouted DuraCeramic tile floor should be sealed with Congoleum DS200 DuraCeramic Joint Sealer to lock out surface water and aid cleaning. Sealing is highly recommended for all un-grouted DuraCeramic and DuraCeramic Dimensions floors. • Condition the room(s) and all flooring and setting materials at a constant temperature between 65°F (18°C) and 85°F (29°C) for 48 hours prior to, during, and 48 hours after installation. Thereafter, maintain a room temperature between 55°F (13°C) and 100°F (38°C). • W hen installing flooring from two or more cartons, check the code on the side of the cartons to ensure that the pattern and shade numbers are the same. Mix tiles from several different cartons to achieve the best appearance. INSTALLATION ACCESSORY MATERIALS • For best visual results: For DuraCeramic the directional arrows printed on the back of the tile should be installed following the illustration in (Fig. 1), with tiles turned randomly, i.e. north, south, east and west. For Ovations, install with directional arrows pointing in the same direction as shown in (Fig. 2). For DuraCeramic Dimensions, install all tiles with arrows pointing in the opposite direction following the illustration in (Fig. 3). • D S100 DuraSet Adhesive – For all approved floor applications. • DuraCeramic Premixed Grout – For joints on grouted floor tiles. • DS200 DuraCeramic Joint Sealer – For joints on ungrouted DuraCeramic and DuraCeramic Dimensions floor tiles only. • DuraCeramic Installation Accessory Kit – For grouted applications. • Congoleum UnderFlor – Floating Underlayment System. RECOMMENDED USE DuraCeramic and DuraCeramic Dimensions are recommended for residential and light commercial use in dry, interior, heated areas. Ovations is only recommended for residential use in dry, interior, heated areas. Fig. 1 - Turn tiles as shown. Fig. 2 - Arrows in the same direction. Fig. 3 - Install with arrows pointing in the opposite direction. 3 Installation Accessories Information DS100 DuraSet Adhesive DS200 DuraCeramic Joint Sealer DuraCeramic Premixed Grout Order Code DS100 DS200 Use specific color code Description Solvent free, acrylic, pressure- sensitive adhesive Water-based, flexible acrylic sealer Premixed sanded, acrylic grout Use Installing tile over all approved floor surfaces For sealing joints in ungrouted DuraCeramic and DuraCeramic Dimensions floors only. For use with DuraCeramic, DuraCeramic Dimensions and Ovations in grouting joints 1/8” to 1/4” wide. Can also be used for grouting most ceramic, quarry and porcelain floor tile. Limitations Not recommended for solid vinyl tile, rubber tile, or resilient sheet products. Not recommended for walls, or vertical surfaces, ceramic, porcelain, natural stone, or Ovations. Not recommended for nonvitreous tiles or natural stone, exterior use, shower floors or underwater use. Coverage 200 to 250 sq. ft. per gallon 320 sq. ft. per 8 oz. bottle Joint Width Approximate Coverage Sq. Ft./Qt. Sq. Ft./Gal. 1/8” (3.2mm) 80 (7.4m2) 325 (31m2) 3/16” (4.8mm) 70 (6.5m2) 275 (26m2) 1/4” (6.4mm) 55 (5m2) 225 (21m2) Applicator 1/16” wide, 1/32” deep, Applicator nozzle included 1/32” apart , trowel blade adapter included in 1 and 4 gallon containers only. Hard rubber float or green epoxy float. Cleanup with firm sponge and 3M® white pad. Working Time 12 hours. Dry to tack - N/A 45 to 60 min. under normal conditions. 10 minutes - for best results apply grout in a 20 sq. ft. area on floors and clean up immediately. Set Up Time N/A Tack free -1 hour Set up - 8 hours 16 to 24 hours Clean Up Wet - Soap and water Dry - Clean cloth dampened with mineral spirits.* Wet - Water Dry - Mineral spirits (Caution: Mineral spirits is flammable) Wet - Water Dry - Household ammonia cleaner. Do not use grout haze removers. Color Pale blue, turns clear when White, turns clear when dry tacky dry Popular versatile colors available Tracers Dark Red N/A N/A Unit Size 1 quart; 1 gallon; 4 gallons 8 oz. bottle 1 quart; 1 gallon Shelf Life 1 year if unopened 1 year if unopened 2 years, if unopened Freeze/ YesYesYes Thaw Stability Flammable NoNoNo Cautions Potential skin and eye irritant Potential skin and eye irritant Potential skin, eye and respiratory irritant DS100 and DS200 - WARNING: Potential eye and skin irritant. DuraCeramic Premixed Grout - WARNING: Potential eye, skin and respiratory irritant. * Mineral spirits - Caution: Flammable material; read and follow cautionary statements on label. 4 Product Information Specifications and Recommended Usage Product Information DuraCeramic DuraCeramic Dimensions Size (nominal) 15 5/8” x 15 5/8” (39.7 cm x 39.7 cm) 12” x 24” (30.48 cm x 60.96 cm) 14” x 14” (35.6 cm x 35.6 cm) Gauge (nominal) .160” (4.1mm) .160” (4.1 mm) .140” (3.6 mm) Packaging 10 pieces/carton; 17 sq. ft.; 1.58 m2 10 pieces/carton; 20 sq. ft.; 1.86 m2 15 pieces/carton; 20.4 sq. ft.; 1.90 m2 Shipping Weight 30.5 lbs./carton 36 lbs./carton 32.7 lbs./carton NBS Smoke Density Passes Passes Passes Critical Radiant Flux (ASTM E648 >0.45w/cm2) Passes PassesPasses Motor Vehicle FMVSS 302 Passes Passes N/A Static Load Limit 250 psi 250 psi 250 psi Slip Resistance Meets ADA Recommendations Meets ADA Recommendations Meets ADA Recommendations PEI Rating 3-4 3-4 N/A Installation Method Grouted or Traditional Edge-to-Edge Fit (Ungrouted) Grouted or Traditional Edge-to-Edge Fit (Ungrouted) Grouted or Traditional Edge-to-Edge Fit (Ungrouted) Subfloor Application On, above or below grade level Adhesive Congoleum DS100 DuraSet Adhesive Grout DuraCeramic Premix Grout DuraCeramic Premix Grout DuraCeramic Premix Grout Joint Sealer (Recommended for ungrouted floors) DS200 Joint Sealer DS200 Joint Sealer Not recommended Suggested Usage Warranty Residential/Light Commercial Residential Residential - Lifelong Limited /Light Commercial - Residential 20 Years Five-Year Limited Commercial Flooring Installations • T he use of a high-quality latex primer that is specifically designed to improve adhesion may be used over wood, porous concrete and patching compounds prior to adhesive application. The primer will help seal the surface and tie down dust that can interfere with the adhesive bond. Do not use paint primers. Special Installation Tools • • • • Ovations Notched trowel (1/16” wide, 1/32” deep, 1/32” apart) 100-pound, three-section, steel roller Grout tools and spacers for grouted applications 18” tile cutter - optional Concrete Floors Concrete must be clean, dry, and free of paint, curing, hardening and parting compounds, sealers, and old adhesive residue. Moisture vapor emissions should not exceed, 5 lbs./1,000 sq. ft./24 hrs. when tested with the calcium chloride kit or 80% RH when tested using ASTM F2170 with a pH range between 5 - 9. Do not install DuraCeramic, DuraCeramic Dimensions or Ovations over expansion joints; instead, cut the tile neatly to each side of the joint and fill it with an elastomeric polyurethane joint filler or cover with an expansion plate cover. Subfloor Recommendations DuraCeramic, DuraCeramic Dimensions and Ovations may be installed directly over dry concrete on all grade levels, suspended wood, qualifying old resilient floors, ceramic tile and terrazzo. DuraCeramic, DuraCeramic Dimensions and Ovations can also be installed over Congoleum UnderFlor, an optional floating underlayment system by Congoleum. The surface must be clean, dry and free of dust, dirt, grease or other extraneous material that will inhibit bonding. Thoroughly vacuum floor to remove dust. Wood Floors Wood subfloors must be structurally sound and free of movement with at least 18” of well-ventilated air space below. Single layer floors and stripwood floors must be covered with a 1/4” or heavier underlayment to achieve a total subfloor thickness of 1”. Position underlayment joints so they offset the joints in the tile by at least 3”. Sand underlayment joints level and fill gaps wider than 1/32” with the recommended patching compound. • D eviations in the flatness of the subfloor cannot exceed 1/16” in 1’ or 3/16” in 10’. Check the surface with a straightedge and fill low areas with a portland cement-based latex patching compound. Gypsum-based patching compounds are not recommended. 5 Subfloor Recommendations Subfloor Construction/Comments Materials Congoleum UnderFlor Notes Congoleum UnderFlor • UnderFlor is an underlayment system for floating installations of DuraCeramic, DuraCeramic Dimensions and Ovations over a variety of substrates in lieu of direct bonding. See detailed instructions on page 7. The subfloor system for floating surface must be smooth, solid and dry. Wood • Double layer construction over joist or trusses on 16” centers with at least 18” of well-ventilated air space. • Install 1/4” or heavier under-layment over strip wood, single layer wood floors and APA-rated Sturd-I-Floor Systems. Subfloor must be solid and free of movement. Install according to panel manufacturers’ written instructions. Concrete • On, above and below grade level. • Radiant-heated floors not to exceed 85°F (29°C). Moisture vapor emissions not to exceed 5 lbs or 80% RH. Light Weight Concrete (Residential Application only) • Minimum 100-pound dry density • Installation over gypsum-based acoustical toppings is not recommended unless Congoleum UnderFlor is used. Confirm adequate adhesion to substrate. Resilient Floor (See WARNING on inside cover) • Smooth, non-cushioned sheet flooring and vinyl composition tile. • Embossed non-cushioned and thin cushioned vinyl flooring can be prepared with embossing leveler in residential applications. • Do not install over soft, heavy cushioned floors, flooring with a cushioned backing, self-adhering tile or tile installed below grade level. Must be single layer, fully adhered and well bonded. Remove wax or polish. Ceramic and Stone • Ceramic, marble and granite. Fill grout joints and level floor. Carpet/ Laminate • Not recommended. Remove Patching Compound • Portland cement-based compound such as Ardex Feather Finish, Mapei Plani-Patch or equal. • Gypsum-based patching compounds are not recommended. Refer to manufacturers’ instructions for use and applications. Roll Sizes UF120 – 6’ x 180’ (120 sq. yds. or 1080 sq. ft.) UFB07 – 6’ x 16.7’ (11.11 sq. yds. or 100 sq. ft.) Recommended Use Underlayment • APA underlayment grade plywood with fully sanded face. • Hardwood and veneer under-layment panels. • Lauan plywood, particleboard, oriented strand board and chipboard create a higher risk for installation and adhesive failure and are not recommended unless warranted by the panel manufacturer or supplier. • Not recommended over cement backer-boards, glass mesh mortar units or acoustical cork. UnderFlor is an all-in-one underlayment system that provides an economical solution for installing DuraCeramic, DuraCeramic Dimensions and Ovations as a floating flooring system over a variety of subfloor surfaces. Now, one underlayment covers it all; wood, concrete, most old hard surface flooring, gypsum topping, even old adhesive residue and painted surfaces. Congoleum UnderFlor is constructed in 6’ wide rolls, and since it is a floating underlayment, it requires no fasteners or special tools so it’s quick and easy to install. • Residential applications on all grade levels • Interior use in dry, heated areas • Do not install over ramps, in showers or other wet areas General Information • A lways roll sheets of Congoleum UnderFlor tightly around a tube with the vinyl side out for storing and transporting. Avoid distorting Congoleum UnderFlor. • Condition the room and all flooring materials at a constant temperature between 65°F (18°C) and 85°F (29°C) for 48 hours prior to, during and 48 hours after installation. • A ll UnderFlor underlayment and finished flooring must be installed with a 1/4” space around the perimeter of the room to allow for expansion and contraction of the flooring system and subfloor. Undercut door casing and slide finished flooring under for a finished appearance. • Use DS100 Adhesive only for installing Congoleum DuraCeramic, DuraCeramic Dimensions and Ovations over Congoleum UnderFlor. Hard setting adhesives should not be used with Congoleum UnderFlor. Congoleum UnderFlor Installation Install Congoleum UnderFlor with the vinyl side down just prior to installation of finished flooring. Determine the appropriate seam location and direction of the underlayment (depending on the finished flooring selection). Important For tile installation, position UnderFlor with seams at least 4” away from the joints in the finished floor tile. (Fig. 4). Fig. 4 – Position seams at least 4” away from tile joints. 6 Congoleum UnderFlor Substrate Recommendations UnderFlor can be installed over the following surfaces: Subfloor Construction/Comments Materials Wood Structure Fig. 5 – Install UnderFlor with seams perpendicular to the long dimension of the DuraCeramic Dimensions f looring. For DuraCeramic Dimensions always install UnderFlor with seams running perpendicular to the long dimension of the tile flooring (Fig. 5). Install tiles with staggered end joints positioned at least 4” away from the seams in the Congoleum UnderFlor. Unroll the first sheet and trim it to fit allowing a 1/4” space between the edge of the sheet and the wall. Unroll the second sheet and position it with the seam edge butted lightly up to the first sheet. If necessary, to adjust the seam location to ensure proper placement, overlap the sheets and double-cut a new seam in the desired location. Use a straightedge and utility knife to cut the seam. Suitable Packaging Tapes Include: • Scotch® 3850 Packing Tape • Duck ™ Tape Standard Packaging Tape • Shurtape® HP Series Do not use masking tape, fiber reinforced tape, duct tape or other thick tapes that might telegraph through the finished flooring. Weather damaged or rough surface materials must be sanded smooth. Gaps wider than 1/8” should be filled level. Concrete • On, above and below grade level. • Radiant-heated floors not to exceed 85°F (29°C). Moisture vapor emissions not to exceed 5 lbs or 80% RH. Fill depressions and cracks wider than 1/8”. Gypsum Topping and Light Weight Concrete • Minimum 100-pound dry density • Minimum 3,000 psi compression rating is required. Fill depressions and cracks wider than 1/8”. Resilient Floor • Smooth, or textured sheet flooring • Vinyl composition tile • Do not install over soft, heavy cushioned floors, flooring with a cushioned backing or tile installed below grade below. Must be single layer, fully adhered and well bonded. Ceramic and Stone • Ceramic, marble and granite. Fill grout joints and level floor. Old Adhesive and Residue and Paint • Adhesive Residue - Scrape to remove heavy spots and cover with a 4 mil sheet of poly film. • Paint - Remove loose paint. Follow recommended work practices for adhesive and paint removal. Install finished flooring immediately after installing Congoleum UnderFlor. Installing DuraCeramic, DuraCeramic Dimensions and Ovations over Congoleum UnderFlor Follow installation instructions for the finished flooring being installed. Install finished flooring with Congoleum DS100 DuraSet Adhesive using the recommended trowel notch size. Do not apply excess adhesive. Allow adhesive to dry completely to a tack prior to flooring installation. Slight growth (buckles) in the UnderFlor may occur immediately after adhesive application. This is normal and will not affect the finished flooring installation. Install finished flooring allowing a 1/8” to 1/4” space around the entire perimeter. If necessary to adjust or remove a tile, use a heat gun to warm it up first. Roll finished flooring on completion of the installation. All finish trim and transition moldings must be installed so they do not bind or restrict the finished flooring from moving when expansion and contraction occurs during seasonal changes. Fasten the trim to the wall not to the subfloor. Do not drive fasteners into the floor or underlayment. Seal all areas that may be exposed to surface spills, i.e. tubs, toilet and showers with a silicone caulking. Subfloor must be smooth solid and free of movement with at least 18” of well ventilated air space below. Underlayment • APA underlayment grade plywood. • Oriented Strand Board (OSB) • NPA rated Particleboard Tape the sheets together with 2” wide clear packaging tape or other thin single face plastic tape available through office supply stores and most home centers. Apply the tape, centered directly over the top of the seam edges. Roll the tape with a steel seam roller. • Double layer construction over joist or trusses on 16” centers. • Single layer floors constructed with APA Rated Sturd-I-Floor T&G Panels, minimum 23/32” over joists or trusses on 19.2” centers. Notes DURACERAMIC INSTALLATION Tile Layout • Layout is slightly different for grouted and ungrouted floors. The grout line width must be added to the tile dimension for layout on grouted floors. Additional chalk lines are also used to keep the joints straight. DuraCeramic nominal tile size is 15 5/8” x 15 5/8”. DuraCeramic Dimensions nominal tile size is 12” x 24”. Ovations nominal tile size is 14” x 14”. • It is important to avoid positioning the tile joints directly over underlayment joints or seams in UnderFlor or existing flooring. If this should occur, reposition chalk lines to offset joints by at least 3” or half of the tile dimension. 7 DuraCeramic DuraCeramic (15 5/8”x 15 5/8”) Dimensions (12”x24”) 1 /2 Drop Layout • Snap a second perpendicular chalkline 12” away from the first perpendicular line (Fig. 8). Complete a dry layout in the first 2 rows starting from the perpendicular chalklines. If the border tile in either row is less than 6”, adjust the perpendicular lines 6” in either direction. Ovations (14”x14”) Square or Straight Yes Yes Yes Diagonal Yes NoYes ½ Drop Yes Yes Yes 1/3 Drop No Yes No Paver No Un-grouted only No Herringbone No Un-grouted only No Basic Square Layouts • P lace a mark in the center of the floor at each end of the room. (AB) Then snap a chalk line between the marks. • F ind the center of the line and snap a second chalk line at a right angle (CD); use the 3’, 4’, 5’ method to form a right angle (Fig. 6). Figure 8 - 1/2 Drop Layout. 1/3 Drop Layout • Snap two additional chalklines, one 8” and the other 16” away from the center perpendicular line (Fig. 9). Complete a dry layout in the first 3 rows starting from the center perpendicular chalkline. If the border tile in any of the 3 rows is less than 4”, adjust all three perpendicular lines 4” in either direction. C A B 8” 8” D Fig. 6 - Square layout. • M ake a dry layout in one quadrant along the center and perpendicular chalk lines. Remember to allow the desired grout line space between the tiles. A story pole (board marked with tile dimensions, including grout line width) can also be used in place of a dry layout. Center Line Figure 9 - 1/3 Drop Layout. • M easure the distance between the last whole tile and the wall. If the distance is less than half a tile, snap a new chalk line one-half the dimension of a full tile away from the original chalk line (Fig. 7). This will provide a balanced layout with larger cut tile at the border. Note: Chalk lines can be easily removed or difficult to see after applying adhesive over some subfloor surfaces like old flooring and concrete. To avoid loosing the lines, mark the subfloor with a pencil and a straightedge, directly over the chalk lines. Adhesive Application Congoleum DS100 DuraSet Adhesive is a pressure-sensitive adhesive that must be allowed to dry completely to a tack before setting tiles. • A pply the adhesive with the trowel blade adaptor included with the adhesive. The recommended trowel notch size is 1/16” wide, 1/32” deep, 1/32” apart. • Spread the adhesive over one-half of the subfloor and a few inches beyond the center chalk line. • A llow the adhesive to dry completely to a tack before installing the tile. Normal dry to tack time is about 45 to 60 minutes; longer in cool or humid conditions. The adhesive will turn from light blue to clear when tacky dry and will not transfer to the finger when firmly touched. Do not use fans to accelerate adhesive drying time. Fan drying can cause the top surface of the adhesive to dry prematurely, trapping residual moisture in and preventing the adhesive from fully curing. Fig. 7 - Adjust layout at center lines for larger border tiles. • W hen installing DuraCeramic Dimensions in a 1/2 drop layout or a 1/3 drop layout it will be necessary to snap additional chalklines for starting locations. First complete a basic square layout with center and perpendicular lines. Normally the tiles are laid with the long dimension parallel with the long dimension of the room. • Tile must be installed within 12 hours after adhesive turns clear. 8 Setting Floor Tiles • Position two spacers along the edge of adjacent tiles, then lay the next tile gently against the spacers without forcing it into place (Fig. 13). Continue to set the tiles in straight rows to complete each section (Fig. 14). Follow the chalk lines to keep the joints straight and make minor adjustments if necessary. Remove the spacers immediately after setting each tile. • C arefully position the first tile into the adhesive at the intersection of the chalk lines (Fig. 10). The tile will bond instantly on contact so it must be positioned accurately without sliding it. Press the tile firmly into the adhesive. Follow the procedures below for grouted and ungrouted floors. Fig. 10 - Positioning tiles. Grouted Floors • T he desired grout line width should be determined prior to starting the flooring installation. It is important to understand that the finished grout line will be 1/16” to 3/32” wider than the space between the tiles, since the grout will extend onto part of the radius along the top edge of the tile (Fig. 11). Fig. 13 - Position spacers before setting the tile. GROUT Fig. 11 - The finished grout line width is wider than the space between the tiles. Spacer Size Actual Grout Line Width 1/8” 3/16” 3/16” to 7/32” 1/4” to 9/32” 1/4” Fig. 14 - Set tile in straight rows. Ungrouted Floors 5/16 to 11/32” • W hen installing an ungrouted floor, continue setting the tiles in a stair-step pattern along the center and perpendicular lines (Fig. 15). Hold the tile in a low angle to the floor and position it tightly against the previously laid tile. Press it firmly into the adhesive. Continue working toward the walls to complete the first quadrant before starting the next. Check to make sure corners are lined up and adjust if necessary to prevent run-out. • U se spacers to maintain the joint width. Small pieces of DuraCeramic or 1/8” tile, cut into 1” squares, work very well as spacers, depending on the desired grout line width. • If standard tile spacers are used, it will be necessary to remove one leg of the spacer (Fig. 12) otherwise it will interfere with positioning the tile. Stand spacers on end. Do not place tile spacers flat at the intersection of tiles; they can become bonded, making it difficult to remove them without damaging the edge of the tile. Fig. 15 - Install ungrouted f loors following a stair-step pattern. Fig. 12 - Use spacers with one leg removed. 9 Grouted and Ungrouted Floors • Make a dry layout in one quadrant along the center and perpendicular chalk lines. • Measure the distance between the last whole tile and the wall. If the distance in either row is less than one-forth of the diagonal dimension of the tile, adjust the starting point and snap a new chalk line 1/4 of the diagonal dimension of the tile away from the original chalk line (Fig. 18). This will provide a balanced layout with larger cut tile around the perimeter. • S pread the adhesive on the second half of the floor so it can dry while you are cutting and fitting the last row of tiles along the wall. Complete the second half of the room following the same procedures. • Roll the floor slowly, in both directions, with a 100-pound, three-section roller within one hour after setting the tiles (Fig. 16). Re-roll the entire floor immediately before grouting or applying joint sealer. Fig. 16 - Roll the floor within one hour after setting tiles. Fig. 18 - Adjusting chalk lines for a diagonal Layout. Cutting Tile to Fit Herringbone Layout for Un-grouted DuraCeramic Dimensions Only The last row of tiles will need to be cut to fit to walls and other vertical surfaces. (Remember to subtract the grout line dimension for grouted floors). Allow a 1/8” space for expansion between the edge of the tile and the wall. • The Herringbone layout requires only a basic square layout with a center and perpendicular chalkline. Complete a dry layout starting at the intersection of the chalklines to determine the size of the cut border tile. If the border tile is less than 6” adjust the chalkline 6” in either direction. Tip: Spread adhesive in 3 quadrants (starting quadrant and adjacent quadrants) when installing a herringbone layout (Fig. 19). Straight Cuts • M easure the distance between the last whole tile and the wall. Subtract the dimensions for the grout and expansion space. Use this dimension to mark the tile. • Place a square or straightedge over the marks and score the surface with a sharp utility knife. Break the tile over the score mark by flexing it downward. • Install the tile with the cut edge against the wall. Irregular Shapes • Scribe the tile to fit. • Warm the tile with a hot air heat gun. Score the surface with a sharp utility knife and break the tile over the score mark by flexing it downward or cut the tile with a coping saw. CUSTOM FLOOR INSTALLATIONS Diagonal Layouts (For DuraCeramic and Ovations ONLY, not for use with DuraCeramic Dimensions) Fig. 19 - Adjust the chalkline 6” in either direction if necessary to achieve a larger border tile. After completing dry layout spread adhesive in 3 quadrants. • L ay out the center and perpendicular lines as previously described for a square layout. Place a mark on each line an equal distance away from the center point (distance from center is arbitrary). • Use a slightly larger arbitrary size and swing an arc on both sides of each line from points E, F, G, H (Fig. 17). Snap diagonal chalk lines at the point where the marks intersect. If done correctly, the chalk lines will intersect at the center point. Fig. 17 - Diagonal Layout. Installing Borders and Insets • Borders can be created easily by using an accent color or different size tile on a square layout. Plan the layout to allow for a uniform border size using full size tile in the field if possible. When using a square border with a diagonal layout, it is necessary to prepare the cut edge of the diagonal tile where it meets the border. 10 Finishing Cut Edges for Borders and Insets • Use the tip of a hard rubber float and fully pack the grout into the joints (Fig. 21). Hold the float in a low angle and press firmly with short strokes at a right angle to the joint. • When installing tile with a diagonal layout and a square border, it will be necessary to prepare the cut edge of the diagonally cut tile. First cut the tile to the desired size. Then heat the cut edge and back of the tile with a heat gun to soften it. Place the tile on a flat surface and roll the edge with a steel hand roller to turn the edge downward, forming a slight radius (Fig. 20). Allow the tile to cool before installing it. Fig. 21 - Pack the grout into the joints. • Extend the grout a few inches in to the next row of tile so water does not run into the unfinished joints during cleanup (Fig. 22). Fig. 20 - Roll the cut edge to form a slight radius. Grout and joint sealer application Grouting Floors • D uraCeramic, DuraCeramic Dimensions and Ovations can be grouted immediately or within 24 hours after setting the tiles. • Tiles must be grouted using DuraCeramic Premix Grout. This exclusive premixed acrylic grout is designed for high flexural strength and adhesion to the edge of the tile. This feature provides durability to resist cracking from thermal dimensional changes and normal subfloor deflection. Traditional cement grouts are not recommended and will not perform properly. Fig. 22 - Extend grout a few inches into the next row. • Remove excess grout from the surface of the tile by holding the float at a 45° angle to the floor surface and moving diagonally across the joints. Grout Application Initial Cleanup Tools and Equipment • Hard, green, rubber epoxy float • Firm, square-edge sponge • 3M® white nylon scrubbing pad • Spray bottle of water • Water buckets • Rubber gloves • S afety glasses Soft grout floats and soft sponges are not recommended because they tend to pull the grout out of the joint, leaving it shallow. Initial cleanup should be done immediately after finishing each section. The faster the grout is removed from the tile, the easier it is to clean up. The DuraCeramic installation accessory kit contains the recommended pads and sponge to make clean-up easier. • Apply a light mist of water with the spray bottle over the grouted tiles and allow it to remain on the surface for at least 30 seconds. • Use a slightly wet 3M white nylon pad to loosen the grout residue. Apply light pressure while moving the pad in a circular motion (Fig. 23). Surface Preparation • R e-roll the floor just before grouting and check to make sure all edges are tightly seated in the setting adhesive. The joints must be clean and dry. Remove any adhesive smears from the surface and edges of the tile with mineral spirits before grouting. Application • Always wear rubber gloves when working with grout. • Start grouting floors at the far end of the room and work toward the entrance. • Apply grout in small sections, up to 20 sq. ft. and cleanup immediately or before grout films over (approximately 5 minutes). Fig. 23 - Use a 3M white, nylon pad to loosen grout residue. 11 • U se a firm square edge sponge to remove the excess water solution. Use light pressure and wipe diagonally across the joints (Fig. 24). Do not allow the water to flow into the ungrouted joints or accumulate in finished areas. IMMEDIATELY AFTER INSTALLATION • Install or replace base moldings and return furniture to the room by rolling or sliding them over strips of hardboard. • Use acrylic caulking at bathtubs, showers and other wet areas to prevent water from seeping under the floor. • Wait 48 hours before damp mopping the floor and at least 5 days before wet mopping or washing. Adhesive smears can be removed with mineral spirits. REPAIR DuraCeramic, DuraCeramic Dimensions and Ovations can be repaired easily if it is necessary to replace a tile. Grouted Floors • Use a heat gun to warm the grout along one edge of the tile. The grout will soften when heated. • Place a straight edge over the center of the grout line and cut the grout with a sharp utility knife (Fig. 25). Fig. 24 - Wipe diagonally across the joint to remove excess water. • T hen rinse the sponge in clean water and wipe diagonally again to shape joints evenly and remove any remaining grout residue. Change rinse water frequently. Clean tools with water while grout is wet. If allowed to dry, remove with an ammonia-based window cleaner. Final Cleanup • Allow grout to dry for 24 hours. • Remove any remaining grout haze with an ammonia-based window cleaner or a dilute solution of 1/4 cup household ammonia to one gallon of warm water. Apply a small amount of the solution over a small section and allow it to remain for about 30 seconds. Use a clean sponge mop or a 3M nylon white pad to loosen the grout haze. Rinse with fresh water and buff with a soft, dry terry cloth towel. Do not use grout haze removers or solvents. Fig. 25 - Cut along the center of the grout line after heating it. Keep all traffic off newly tiled floors for 24 hours. Resume normal traffic after 48 hours. • Remove as much of the grout as possible using care to avoid cutting into the edge of the adjacent tile. Repeat this process on all four sides of the damaged tile. • Next, heat the tile a few inches in from the corner. While the tile is warm, drive a putty knife or screwdriver into the heated area with a hammer (Fig. 26). Joint Sealer Application DuraCeramic DS200 Joint Sealer is designed to keep surface water and dirt from penetrating ungrouted floor joints. Apply joint sealer to the tile joints only. Surface Preparation • R oll the floor with a 100 lb., three-section roller just before sealing the floor and check to make sure all edges are tightly seated in the setting adhesive. The joints must be clean and dry. Remove any adhesive smears from the surface and edges of the tile with mineral spirits before sealing. Vacuum the floor to remove dust and loose particles. Application • • • • • • • • S hake the applicator bottle and allow air bubbles to dissipate before using. Remove the plastic cap and screw the applicator tip onto the bottle. Cut 1/16” off of the applicator tip to provide a small opening. Start in the far corner of the room and apply a uniform 1/16” bead of sealer in the tile joint. Apply the sealer to the first 2 or 3 rows, then come back immediately and seal the perpendicular (cross) joints in this area before the sealer develops a surface film (about 4 minutes). Repeat this process to seal the entire floor. The color of the sealer will change from white to clear when it dries. If the nozzle becomes clogged, use a straight pin to free the flow. Protect newly applied joint sealer from foot traffic and dust until it dries, (approximately 8 hours). Keep traffic to a minimum and do not wash the floor for the first 48 hours. Use water cleanup for wet sealer and mineral spirits for dry sealer. Caution: Mineral spirits is flammable. Read and follow label instructions. 12 Fig. 26 - Drive a putty knife into the heated area and pry upward. • T hen, pry upward to release the tile from the adhesive. Continue lifting the tile as you heat it until it is completely removed. • To install the new tile, re-apply DS100 DuraSet Adhesive over the exposed subfloor using the flat side of a trowel; it is not necessary to remove the old adhesive. • Allow the adhesive to dry completely to a tack and then reinstall the new tile using spacers to maintain the grout line width. • Roll the tile with a 100-pound, three-section roller. • Re-grout the tile with DuraCeramic Grout following label instructions. Allow grout to dry for 24 hours and remove any remaining grout haze. Ungrouted Tile Floors • T ip: Here’s a tip to make it easier to slide the tape under the edges. Cut the piece of tile that was removed to make it about 1 inch shorter. Cut the thin packaging tape to that dimension. Carefully fasten the tape along the edge of the product overlapping it about 1/4 inch. Turn the piece over so that the tape is now sticky side up and slide it under the cut out edge. Firmly press down on the edge and pull the replacement piece away to release the tape. • U se a utility knife and carefully cut through the joint sealer using care to avoid cutting into the adjacent tiles. • Follow the same procedure for Grouted Floors to remove the tile and re-adhere the replacement tile. • Re-apply DuraCeramic DS200 Joint Sealer along all four sides of the tile to seal the joints. • Carefully lay in the new cut piece of UnderFlor pressing it firmly onto the tape. • Apply DS100 adhesive to the Congoleum UnderFlor and allow it to tack up. • Lay in the replacement flooring and roll it to set it in place. • Roll the replacement piece with a roller to set it. • Re-grout the tile or reapply DS200 joint sealer to finish the repair. Congoleum UnderFlor Repair Techniques Repair techniques are very easy on Congoleum UnderFlor installations. Use these procedures for repairs for DuraCeramic, DuraCeramic Dimensions or Ovations installed over Congoleum UnderFlor. Ungrouted Repair • C arefully score the tile to be removed across the corner edge about 1 inch from the corner. • Apply heat to the area. • Using a putty knife and hammer, position the putty knife over the scored edge and tap it until the corner is released. • Apply heat as you go and carefully begin to pry up the piece from the Congoleum UnderFlor using a putty knife. If you keep the tile heated, it should release without damaging the UnderFlor. • When the piece has been removed, check the adhesive tack. If it is still tacky to the touch, simply position the new piece in place. • If the adhesive is not tacky, reapply adhesive with the flat side of the trowel and let it tack up. Then set the replacement piece into place. • Roll the replacement piece with a roller. PREVENTIVE CARE • Make sure furniture legs have large surface, nonstaining floor protectors. Replace small, narrow metal or dome-shaped glides with smooth, flat glides that are in flat contact with the floor. Glides should be equipped with self-adhesive felt pads to avoid scratching the surface of the floor. The pads should be checked periodically for grit and wear and replaced when necessary. • Heavy furniture or appliances that are not moved often should be equipped with flat, nonstaining composition furniture casters or cups of appropriate size – available square from 1 1/2” to 2 5/8” and round from 1 3/8” to 1 5/8”. • Mobile appliances and furniture should be equipped with easily swiveling casters. They should be at least 2” in diameter with nonstaining hard rubber treads at least 3/4” wide. Do not use ball-shaped casters. • Place mats at outside entrances to prevent dirt, grit and soil from being tracked onto your floor. Caution: DuraCeramic, DuraCeramic Dimensions and Ovations, like other types of hard-surfaced floors, can become slippery when wet. Allow time for the floor to dry after washing. Immediately wipe up wet areas from spills or wet feet. Place mats at outside entrances to prevent water, snow or ice from being tracked onto your floor. Improper polishes or finishes can also cause slipperiness. Grouted Repair • Use a heat gun to warm the grout. • Using a sharp utility knife, carefully score the joint, cutting through the grout. Make sure that you do not apply a lot of pressure because you do not want to cut into the Congoleum UnderFlor. Carefully score the tile to be removed across the corner edge about 1 inch from the corner. • Apply heat to the area. • Using a putty knife and hammer, position the putty knife over the scored edge and tap it until the corner is released. • Apply heat as you go and carefully begin to pry up the piece from the Congoleum UnderFlor using a putty knife. If you keep the tile heated, it should release without damaging the UnderFlor. • When the piece has been removed, check the adhesive tack. If it is still tacky to the touch, simply position the new piece in place. • If the adhesive is not tacky, reapply adhesive with the flat side of the trowel and let it tack up. Then set the replacement piece into place. • Roll the replacement piece with a roller. • Re-grout the tile with DuraCeramic grout following label instructions. Allow grout to dry for 24 hours and remove any remaining grout haze. REGULAR CARE • Sweep or vacuum regularly to remove grit and sand that can abrade, dull or scratch your new floor. Do not use a vacuum with a beater brush, because it may damage the floor’s surface. • Wipe up spills promptly with a damp cloth or mop. • Wash the floor with Congoleum Bright ’N Easy No-Rinse Cleaner or other suitable floor cleaner. CAUTION: Avoid one-step “mop and polish” products, dishwashing liquids and oil-based cleaners. These may leave a residue which can attract dirt and dull the floor’s finish. Avoid cleaners that contain abrasives or solvents which may permanently damage the floor. Replacing the Congoleum UnderFlor • Do not use silicone sealers or penetrating sealers on the tile surface. A copolymer or acrylic grout sealer compatible with acrylic grouts may be used on the grout. Do not use a penetrating silicone sealer on the grout. • Do not buff the floor. Do not apply polish to DuraCeramic or DuraCeramic Dimensions, Floor Polish use is optional for Ovations. If the Congoleum UnderFlor is cut or damaged during the repair procedure and needs to be replaced, follow these procedures. • Using the piece that was removed as a template, cut a fill piece of Congoleum UnderFlor. • Slide pieces of thin, clear, sticky, one-sided packaging tape centered under the cut out edges. 13 WARRANTY Residential DuraCeramic and DurCeramic Dimensions Limited Warranty Congoleum provides a lifelong warranty that your floor: • will be free of manufacturing defects • will not wear out • will not fade • will not stain DuraCeramic and DuraCeramic Dimensions featuring ScotchgardTM Protector provides additional warranty provisions for 15 years: • will be easy to clean • will repel dirt and grime The Residential DuraCeramic and DuraCeramic Dimensions Limited Warranty covers material for the period of the warranty, and reasonable labor costs for five years if professional installation was paid for when the original floor was installed. When installed in a light commercial application, DuraCeramic and DuraCeramic Dimensions carry the Congoleum Five-Year Commercial Limited Warranty. Five-Year Commercial DuraCeramic and DuraCeramic Dimensions Limited Warranty The Five-Year Commercial Limited Warranty means that the floor: • will be free of manufacturing defects • will not discolor from mold, mildew or alkali The Five-Year Commercial Limited Warranty covers material for the warranty period, and reasonable labor costs during year 1 if professional installation was paid for when the original floor was installed. For years 2 through 3, covers material and 50% of reasonable labor costs if professional installation was paid for when the original floor was installed. After the third year, covers material only; labor will not be paid. The Residential and Commercial warranties apply to DuraCeramic and DuraCeramic Dimensions only and exclude grout and installation services. The Residential warranty applies to Ovations only and excludes grout and installation services. For additional information and complete warranty information contact Congoleum Corporation, Dept. C, 3500 Quakerbridge Road, P.O. Box 3127, Mercerville, NJ 08619. Our telephone number is 1-609-584-3000 and our web address is www.congoleum.com Ovations Residential Limited Warranty Ovations installed in a residential setting, is covered by a 20-year limited warranty. This means that your floor: • • • • will be free of manufacturing defects will not wear out will not fade will not stain The 20-year Residential Limited Warranty covers material for the period of the warranty and reasonable labor costs for five years if professional installation was paid for when the original floor was installed. 3500 Quakerbridge Road, PO Box 3127 Mercerville, NJ 08619-0127 • www.congoleum.com © 2014 Congoleum Corporation Printed in USA M34960114S TRADEMARK LISTINGS: BRIGHT ’N EASY, CONGOLEUM, CONGOLEUM UNDERFLOR, DS100 DURASET, DURACERAMIC and DuraCeramic Dimensions are registered trademarks of Congoleum Corporation. DS200 and OVATIONS are trademarks of Congoleum Corporation. 3M, Scotchgard and the plaid design are trademarks of 3M. FEATHER FINISH is a registered trademark of Ardex, Inc. PLANI-PATCH is a registered trademark of Mapei. SHURTAPE HP SERIES is a registered trademark of Shurtape Technologies. DUCK™ is a trademark of Henkel Consumer Adhesive Inc.
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