There are five very important procedures that must be followed in handling patterned carpets
Storage – Store carpet and adhesives in a dry area. To avoid product distortion in storage, never stack carpet more than two rolls high or stand rolls on end.
Acclimation – Bring all carpet cut sizes and adhesives into space a minimum of 24 hours prior to installation to condition the carpet. Unroll and smooth wrinkles, allowing product to relax. HVAC and lighting systems must be in service. During installation, and 72 hours thereafter, maintain temperature between 65 and 90 degrees F and relative humidity between 20% and 65%.
Subfloor Conditions – Subfloor must be dry, level, and free from dirt, grease, oil, paint, sealer, old adhesives, and other residues. Repair or replace loose flooring substrates.
Patching Concrete Subfloors – Patch cracks in concrete subfloors greater than 1/8” deep with an approved latex patching compound. Use latex additive to mix patching compound, not water. For larger areas requiring leveling, use a cementitious underlayment mix.
Concrete Moisture Content – New concrete subfloors must cure from 90 to 120 days. The moisture emission rate of a concrete floor is expressed in lbs. /1000 square feet/24 hours. Because the test for emission rate requires 72 hours to conduct, proper installation planning is a must. As a general guideline, an emission rate of 3 lbs. or less is acceptable for most carpet. In the range from 3 to 5 lbs., carpet with backings of porous constructions can usually be installed successfully. An emission rate above 5 lbs. is considered unacceptable. To ensure the sub-floor is acceptable for use; moisture test methods ASTM 1869 or ASTM 2170 are REQUIRED before installing carpet. Prior to installing Atlas carpet(s), the adhesive manufacturer should confirm in writing that the site floor conditions meet or exceed their moisture requirements.
Concrete Alkalinity Content – Test all concrete, new or old, for excessive alkalinity. A pH range of 5-9 is acceptable. A reading above 9 requires corrective measures. Consult the adhesive manufacturer for recommended corrective procedures.
On or Below Grade Concrete Subfloors – On or below grade concrete subfloors must have an appropriate vapor barrier
B. CUTTING/TRIMMING OF SELVAGES AND EDGES DO NOT USE FACTORY EDGE FOR SEAMING
Before you get started, all carpet cut sizes should have been conditioned for 24 hours prior to installation. Seam edges must be cut from the face using a loop pile cutter or cushion back cutter such as Roberts 10146 or equivalent. Double cutting, serpentine cutting, and trace cutting are not recommended. A premium quality seam sealer containing UV enhancers is mandatory on all cut edges of every seam.
In preparing the seam, determine the match points and the pile sweep of the pattern on both sides of the seam, making sure that the same pattern size is used for the match points. In some patterns the match point may be 18-19 inches in from the first match point; therefore one must be careful with the primary match point. The primary match point will be found within ½” to ¾” inches from the factory edge. If the carpet has the patented Veratti “Easy Trim” feature, the appropriate cut location is in the narrow gap just inside the black yarn tufted about ¾” inside each edge. Using a dull screwdriver or a similar blunt instrument, run down (lengthwise) a tuft row coinciding with the pattern match line. Cut down this prepared line with the cutting tool, tilting the blade away from the side to be used in order to obtain a smooth edge. Perform the same method of cutting on the adjacent section of the carpet to be seamed (Diagram Nos. 1 & 2). Cross seams must be prepared in a similar manner. Because of the difficulty in obtaining good pattern match in cross seams and fill seams, the material should be selected from the same roll.
Run seams lengthwise to major area(s).
Run major seams parallel to, not across, traffic paths.
Plan major seams so that natural or artificial light does not shine directly across them.
Avoid seams at major pivot points.
Avoid seams which intersect perpendicular to doorways and entrances.
C. DIRECT GLUE DOWN INSTALLATION ADHESIVES
1. Concrete Floors
All foreign matter, grease, paint, wax, oil, dirt, etc., should be removed
Cracks, holes and depressions should be filled with a latex patching material.
Floor surface should be smooth.
Suggest concrete floors be sealed for best results.
As with all installation methods (Direct glue-down, Stretch-in, Double Bond system), the use of appropriate tools may include: power stretcher, knee kicker, dead-man, dry (string) line, stay nails, and a mini or crab stretcher.
Installation Procedures – Direct Glue-Down:
Rolls must be checked carefully for any visible defects before cutting. All rolls must be installed in dye-lot sequence.
Orienting carpet so that the pile lies in the same manufacturing direction is critical. All rolls are back stamped with arrows denoting the manufacturing direction. Align arrows to point in the same direction.
Use the same cutting procedure found under Section B of this procedure.
Loose lay each cut before applying any adhesive, checking carefully for pattern alignment, determining which side must be stretched, if necessary, to match the adjacent pattern. When satisfactory, apply adhesive.
Lay the “short” side into the adhesive starting in the center of the breadth and working in both directions from the center. Use a knee kicker or power stretcher to position along a chalk line. Stretch and nail the carpet runs as needed to attain a reasonable pattern match along the seam. Being a fabric, a perfect pattern match cannot always be achieved. However, with care and skill a good match can be obtained. A cotton head power stretcher can also be used on more difficult patterns. Allow sufficient time to dry before removing nails.
Avoid air entrapment. Roll with 75 lb. linoleum roller in both length and width direction.
Restrict heavy traffic and furniture movement for 24 hours.
To prevent edge raveling at transition borders (wherever carpet meets hard surface flooring), transition strips are required in addition to the proper use of seam sealer.
Premium quality seam sealers containing UV enhancers are mandatory on all cut edges (side seams, cross seams, electrical cut-outs, where carpet abuts hard surfaces, etc.). Installers must apply a 1/8” bead of premium quality seam sealer to the base of the yarn on all cut edges, covering the thickness of the primary and secondary backing without contaminating the face yarns. Before completing the seam, apply a second bead of seam sealer to one side and then place that side into the adhesive on the floor. To weld the seam together, abut both edges of the seam on the floor while the seam sealer is still transferrable.