E03C Flooring

E03C - MATERIAL GUIDES - FLOORING

E03C-1 Laminate Flooring
E03C-2 Laminate Flooring Underlayment
E03C-3 Laminate Flooring Materials
E03C-4 Laminate Flooring moulding, trims, and accessories
E03C-5 Laminate Flooring delivery, storage, and handling
E03C-6 Laminate Flooring Installation

Preface:
This study guide covers laminate flooring and related materials. The information given is a guide only and cannot fully cover all aspects of such flooring and its installation. Specifiers and/or persons selecting such products should verify all facts relative to the particular project requirements.
This study guide does not cover laminated or engineered wood flooring which is included under Hardwood Flooring, Part D03C - Material Guide - Flooring.

To fully understand how to choose the most appropriate laminate flooring for an institutional, commercial, or residential project, a thorough knowledge of the materials and installation requirements is essential. The following information will hopefully assist Designers, Suppliers, Installers, Owners, and others in becoming more aware of flooring issues and aid in choosing an appropriate laminate flooring material and installation method to suit a project's requirements.

1 • LAMINATE FLOORING

.01 What is Laminate Flooring?

Laminate flooring is a manufactured modular flooring product in plank or tile form that consists of a clear alpha cellulose surface wear layer and a thin décor or "image" layer superimposed over one or more phenolic or melamine resin-impregnated papers (similar to a plastic laminate) and a core layer of either medium density fibreboard (MDF), high density fibreboard (HDF), or particle board and a bottom balancing layer for stability. In summary laminate flooring is made up of:
- Overlay (wear) and decorative paper layers in a melamine resin.
- Core layer made of HDF, MDF or particleboard.
- Stabilizing (backing) layer made of special paper.

The surface and décor layers are bonded together under heat and pressure using a continuous pressure laminate (CPL) or a high pressure laminate (HPL) process and then adhered to the core, or they may be directly adhered to the core under heat and pressure using the direct pressure laminate (DPL) process. A variety of other different papers can also be inserted between the core layer and the decorative paper, e.g. a footstep sound insulation layer. The two main processes are:

Direct Pressure Laminate (DPL): In the direct-pressure laminate process the decorative covering layer and stabilizing layer are pressed together onto the core layer.

Composition of DPL Laminate Flooring:

Overlay (wear layer).
Decorative paper (image).
Core layer.
Stabilizing (backing) layer.

High Pressure Laminate (HPL): In the high-pressure laminate process the overlay wear layer and decorative layer are pressed onto a special high-strength paper first and then this high-pressure laminate is then glued to the core layer.

Composition of HPL Laminate flooring

Overlay (wear layer).
Decorative paper (image).
+ high-strength paper.
Core layer.
Stabilizing (backing) layer.

.02 Laminate Flooring Sources

Laminate flooring is manufactured in both North America and Europe and is governed by two standards associations: NALFA and EPLF.

The North American Laminate Flooring Association (NALFA) is comprised of North American manufacturers, distributors, materials providers, and ancillary entities. This organization has by consensus established minimum performance requirements for laminate flooring using established testing methods that include static loading, thickness swell, impact resistance, light resistance, cleanability / stain resistance, wear resistance, dimensional tolerances, and castor chair resistance, which are noted in their "NALFA LF-01, Laminate Flooring Standard".

The Association of European Producers of Laminate Flooring (EPLF) is comprised of those European manufacturers, distributors, materials providers, and ancillary entities who endorse the European Norm standard "EN 13329, Laminate Floor Coverings - Specifications, Requirements, and Test Methods" for such flooring. This standard specifies characteristics, states requirements, and gives test methods for laminate flooring. It also includes a classification system giving practical requirements for areas and levels of use, indications as to where laminate flooring will give satisfactory service, as well as requirements for marking and packaging.

As there are two different sources / standards for laminate flooring, the quality, including that of the photographic image, the structural integrity of the jointing system, and moisture resistance of the core material, amongst other minimum performance requirements may vary between North American and European manufactured laminate flooring. Designers must understand the differences between the applicable standards.

.03 Laminate Floor Performance Testing

All laminate flooring must be tested and certified in regard to specific performance requirements by an independent testing laboratory. Such flooring must undergo re-testing at least every five years or whenever the product is substantially changed to maintain its certification.

When reference is made to performance ratings a laminate product shall meet all of the requirements of the standard in their entirety. Any laminate marked or labelled as being compliant with NAPFA or EPLF standards must meet all of the requirements of the standard.

The NALFA/ANSI or EPLF mark must be indicated on product packaging, labels, or on an information sheet included with each package. The following information must be indicated:

Manufacturer and product names.
Applicable standard.
Usage rating / product class.
Material colour / pattern and batch number.
Nominal dimensions of one floor covering element (panel or tile).
Number of panels or tile in the package.
Coverage area of package in square metres or feet.

.04 Laminate Floor Ratings

Common performance ratings of NALFA and EPLF standards have been itemized under the following headings:

Usage Rating: This rating indicates the overall performance of the flooring under specific classifications ranging from light residential to heavy commercial and is based on such things as wear / abrasion, impact resistance, static load resistance, castor chair resistance, and cleanabilty / stain resistance.

NALFA

Residential (Certification Level 1).
Light Commercial (Certification Level 2).
Commercial (Certification Level 3).

EPLF

Domestic: Class 21 (Moderate), Class 22 (General), Class 23 (Heavy).
Commercial: Class 31 (Moderate), Class 32 (General), Class 33 (Heavy).

Wear / Abrasion Resistance Rating: This rating indicates the degree (minimum number of cycles of an abrasive wheel) that the image (Décor) layer resists abrasive wear-through (in each case the degree of abrasion after a specific number of cycles of cylinder wheels covered with 180 grit aluminum oxide sand paper). The more resistant to abrasion the more durable the flooring will be to heavier traffic wear.

NALFA

Residential: minimum 1800 cycles.
Light Commercial: minimum 2500 cycles.
Commercial: minimum 4000 cycles.

EPLF

Moderate Domestic (Class AC1): minimum 900 cycles.
General Domestic (Class AC2): minimum 1800 cycles.
Heavy Domestic and Moderate Commercial (Class AC3): minimum 2500 cycles.
General Commercial (Class AC4): minimum 4000 cycles.
Heavy Commercial (Class AC5): minimum 6500 cycles.

Impact Resistance Rating: This rating (based on dropping large and small diameter steel balls from a specific height) indicates to some degree the impact resistance (resistance to fracture) of laminate flooring.

Residential: 800 mm (31.5").
Light commercial: 1000 mm (39.4")
Commercial: 1400 mm (55.1")

Residential: 200 mm (7.9").
Light commercial: 200 mm (7.9").
Commercial: 500 mm (19.7").

Class IC1 for moderate domestic to moderate commercial usage.
Class IC2 for general commercial usage.
Class IC3 for heavy commercial usage.

Static Load Resistance Rating: This rating indicates the ability of laminate flooring to resist residual indentation resulting from a static load.
Chair Castor Resistance Rating: This rating indicates resistance to change of appearance and stability of a laminate floor, including joints, under the movement of a castor chair.
Thickness Swell Rating: This rating indicates the degree of swelling due to changes in relative humidity (the core test sample with raw, untreated edges is exposed to water). Swelling may also occur if laminate flooring panels / tiles with untreated or unglued side and end joints are exposed to water from spills or wet mopping floors. This may be mitigated by using a water resistant core material or by manufacturers specific joint assembly / treatment requirements.
Dimensional Tolerance Rating: This rating indicates the dimensional variance between panels / tiles of laminate flooring in respect to thickness, length, width, straightness, and squareness. The tolerances of the tongue and groove assembly when assembled without glue must also be such that permissible opening and height values must not be exceeded when tested. Any discrepancies may be mitigated by tighter production / quality controls
Cleanability and Stain Resistance: This rating is a measure of both the ease of cleaning and stain resistance of laminate flooring to common household substances for residential laminate flooring.

Light / Fade Resistance: This rating indicates the degree that laminate flooring will retain its colour when exposed to a light source having a frequency range approximating sunlight through window glass. It is not intended to show the resistance to continuous exposure to outdoor weathering conditions.

NALFA: to NALFA LF-01 3.3: No effect on Residential, Light Commercial and Commercial grades.

EPLF: to EN / ISO 105 (blue wool scale, Part B02): not worse than 6.

EPLF: to EN 20105 (grey scale, Part A02): not worse than 4.
Other Performance Ratings: These are specific to NALFA labelled products.

                Smoke density to ASTM E662: ≤450.
                Critical radiant flux to ASTM E648: Type 1 or >1.08.
                Wet and dry slip resistance to ASTM C1028: > 0.8.
                Sound Transmission Class (STC) to ASTM E90: >51.

Note: Neither NALFA or EPLF "grade" species of wood used as part of the laminate flooring décor layer, as this is in reality a photographic image that faithfully reproduces the grain and colour of a natural hardwood or softwood.

Designers selecting laminate flooring must satisfy themselves as to the performance, finish, and warranty requirements as well as the availability of laminate flooring with all selected product sources / manufacturers / suppliers before specifying and use.

.05 Laminate Flooring and Moisture

The moisture content of the wood-based core material may vary greatly prior to processing as not only the climatic conditions but also the type of wood used to produce the particles or fibres (bulk density), the shape and size of the fibres or particles, the cross-sectional density profile, the mean bulk density and the bonding agent and bonding agent distribution, etc. are of significance in respect to the hygroscopic properties of the material.

As a wood core product, laminate flooring is subject to the same expansion and contraction caused by an increase or a decrease in its moisture content due to changes in relative humidity or other causes (e.g. moisture vapour from below). This is an intrinsic property of a wood product. The following indicates the mean moisture content by % weight at 65% relative ambient humidity and an ambient temperature of 20°C (68°F):

MDF Medium-density fibreboard: 6 ± 2 %.
HDF High-density fibreboard: 5 ± 2 %.
Fine-grain particle board with PF resin bond: 6 ± 2 %.
Particle board with PF resin bond: 9 ± 2 %.

Even when installed with tight and /or glued joints there is no guarantee of perfect and durable sealed joints and therefore no absolute protection against moisture ingress. In other words, laminate flooring should not be mopped or scrubbed using a large amount of water. And as a general rule laminate flooring should not be installed in areas where excess surface moisture or danger from flooding may occur, such as in laundry rooms, storage rooms containing a hot water tank, bath / shower rooms, etc. unless otherwise approved by the manufacturer.

.06 Laminate Flooring Joints

There are many types of edge joining systems used to connect laminate flooring panels together. Some laminate flooring connections snap together by hand while others require a light tap with a mallet and a tapping block. Still others use a combination of a "snap" click edge and a "bang" or "tap" click at the end of the panels. While most of the various systems work well to secure flooring panels it is important to review the laminate flooring installation instructions carefully before starting any installation.

Some manufacturers also require the application of glue to the tongue-and-groove joints of individual planks and in some cases panel end-to-end joints. This may be a requirement of the joint system and/or to seal the joints so as to protect against the ingress of moisture through the joints. Where this is required the application must comply with the instructions provided by the laminate flooring manufacturer. In some cases the application varies between using a liberal bead in the groove of particle board panels and/or a thinner bead along the top of the tongue or the top of the edge of the groove on MDF and HDF core panels. It is important in all cases that glue is released along the top of the joint when two boards are firmly pushed together under force with the excessive glue wiped off immediately with a damp cloth.

Caution Note: The design authority / specification writer is cautioned against specifying a particular manufacturer or type of adhesive as the laminate flooring manufacturer may have specific recommendations in regard to the type and usage of adhesive for their particular product and installation. The National Floor Covering Association (NFCA) therefore recommends that the Design Authority specify adhesive "as recommended by the laminate flooring manufacturer to suit installation requirements". The grade (standard or premium) and the type (based on VOC content as well as use of water resistant or water proof types) should however be noted where applicable.

LEED Requirements: Where the laminate flooring installation must conform to LEED requirements, the core material and type of adhesive when used (including that for bases and accessories) shall be governed by those requirements. Refer also to Part A14 - Adhesives and Fastenings for general adhesive information.

2 • LAMINATE FLOORING UNDERLAYMENT

.01 Underlayment: The term "laminate underlayment" refers to any product designed for installation over a substrate / sub-floor surface and under the laminate flooring material. The characteristics of the underlayment should be as recommended by the laminate flooring manufacturer to meet the specific project.

Note: This term (underlayment) should not be confused with underlayment panels (a sheathing material applied over subfloor).

.02 Purpose:The purpose for a laminate underlayment may be one or a combination of the following:

To smooth out minor substrate imperfections.
To help protect the laminate material from sub-floor moisture.
To improve thermal insulation properties.
To reduce walking fatigue.
To provide an acoustical separation.

.03 Composition: Laminate flooring underlayment products may be constructed of, but not limited to, one or a combination of the following materials:

Cork.
Frothed foam.
Granulated rubber.
Natural fibre.
Polyethylene film.
Polyethylene foam.
Polypropylene foam.
Polystyrene granulate.
Polyurethane foam.
Rebonded urethane foam.
Sponge rubber.
Synthetic fibre.
Vinyl foam.
Wood fibre.

.04 Properties: A laminate flooring underlayment must meet a number of characteristics:

Acoustical Properties: underlayment may have to provide one or more sound attenuation requirements for impact sound (vibration generated by footfalls or objects coming in contact with the flooring surface that is transmitted to an adjacent room), airborne sound (any airborne vibration such as voices, sound systems, etc., that travels through the flooring system and into an adjacent room), and/or resonating sound (that portion of impact or airborne sound that reverberates or echoes within the room). For a thorough explanation of these requirements refer to A08C - Acoustical Issues.

Note

Compression Resistance: This is the measurement of the force necessary to produce a specified percentage of compression over the entire top area of a given sample. The accepted percentage compression for test methods used to compare flooring underlayment products is 25%. Various ASTM methods may be used to test for compression resistance with results expressed in either kPa or psi. The specific method selected should be noted when reporting results.

Compression Set: This is the deflection of an underlayment specimen under a compressive force and under specified conditions of time and temperature, with the effect on the thickness of the specimen after releasing the compressive force noted. The results are reported as a percentage of the original thickness. Test methods for measuring compression set must require deflection for a period of 22 hrs and release for a period of 24 hrs. The two ASTM tests differ in the thickness of deflection (25% and 50%). The thickness of the test deflection should be noted along with the specific method selected when reporting results.

Density: This is the ratio of the mass weight of the underlayment to its volume. Density is calculated from thickness and weight determinations and expressed in pounds per cubic foot or kilograms per cubic meter.

Water Vapour Transmission Rate: This is the evaluation of moisture resistance properties to determine the rate of water vapour transmission through a given barrier material. The resultant Water Vapour Transmission Rate (WVTR) is the time rate of water vapour flow normal to the surfaces, under steady-state conditions, per unit area.

Tensile Strength: This is the measurement of the force needed to separate or tear the underlayment. Tensile strength measurements may help compare underlayment materials for ease of installation and long-term wear-ability of the underlayment. Standard methods for the evaluation of tensile strength are conducted for both the length and width of the test material and are reported in lbs or kgs of force.

Thermal Resistance (R-value): This is the reciprocal of thermal conductance (C-value). C-value is calculated from the thermal conductivity (k) of a material. Thermal conductivity (k) is the measure of the amount of heat that will be transmitted through a one inch thick piece of homogenous material, one square foot in size, in one hour, when there is a one degree Fahrenheit temperature change. The equation for "k" is: BTU * inch/sq.ft. * hr * deg F. C = k/thickness in inches. R = 1/C.

Thickness: normally measured in inches, mils, or millimeters, thickness is important when evaluating the finished flooring profile height as it relates to adjacent flooring material, doorway clearance and laminate accessory use.

Weight: This is usually expressed in lbs (or ounces) per square foot, or grams (or kgs) per square meter. Weight comparison may be an important characteristic when considering job site material management, ease of installation and freight costs.

.05 Underlayment Tape: 50 mm (2") wide polyethylene or other type pre-approved by underlayment manufacturer. Such tape is used only as directed by the laminate flooring manufacturer.

3 • LAMINATE FLOORING MATERIALS

.01 Laminate Flooring: This composite flooring material is available in two general thicknesses; 8 mm (0.330") and 10 mm (3/8") and as previously noted, consists of a laminate          décor layer surfacing (similar to plastic laminate) and a balancing backer bonded to a manufactured "wood" core material that may be either medium density or high density fibre      board or particle board conforming to either ANSI/NALFA LF-01 for North American manufactured flooring or to EN 13329 for European manufactured flooring. The core may          also be treated to be moisture resistant.

     The décor layer may consist of a wood, ceramic, stone, or other decorative image that is usually available in a variety of patterns, textures, and colours.

     Laminate plank or tile flooring may be complete with square or bevelled edges that may be on two (e.g., on long side of planks) or in some instances on four sides.

     Laminate flooring is manufactured in a number of forms to meet a number of uses:

Laminate Plank Flooring: This type of laminate flooring is available in nominal widths ranging from 200 mm (8") to 300 mm (12") wide and in lengths of 1180 mm (46").

Laminate Tile Flooring: This type of laminate flooring is typically available in nominal 390 mm (15") square tiles although other square and longitudinal sizes may also be available.

Laminate Stair Materials: This laminate material is available from most laminate manufacturers and is used to cover stair treads and risers with laminate flooring. Such stairs are usually contained (boxed) although open stair components may also be available.
- Treads: This is a special piece of laminate wrapped MDF or HDF "flooring" complete with a bullnose nosing sized to suit full tread depth and width.
- Risers: This is a matching laminate piece sized to full tread width and riser height. The riser top is usually covered by the tread bull nose above.
- Nosings: In some cases a separate extruded aluminum nosing may be used with laminate treads with top of nosing flush with laminate tread (or other floor finish at the top of stairs). In wide tread stairs an overlapping nosing secured to substrate may be used to allow laminate flooring treads to float free.
- Note: Verify if overlapping nosings meet code requirements before using.
For availability of types, patterns, colours, and sizes designers must contact the manufacturers / distributors.

.02 Spacers / Expansion Joint Strips: This resilient inert material is required to maintain a constant space in voids at flooring perimeters and at other vertical interfaces. The               material may be strips of cork or closed cell polystyrene with size to suit void width.

.03 Adhesive for Glued Joints: When required by the manufacturer this adhesive (a premixed, water-based type) is used to glue planks-to-planks or tiles-to-tiles and may also be       used to seal cut edges of flooring.

.04 Adhesive for Glued-Down Components: When required and only when recommended by the manufacturer, laminate flooring may be adhered to a substrate using a high               strength premium grade low VOC (solvent-free), alkaline and water resistant type adhesive specially formulated for glue-down application of laminate flooring. The type must           also suit material and substrate types and conditions as recommended by both adhesive and laminate flooring manufacturers. Spread rates for adhesive must be strictly adhered       to. Such adhesive is also used when laminate stair treads and risers are glued to stairs.

.05 Fasteners: When required these must be purpose made screws, nails, staples and machine driven fasteners for flooring and accessories of approved types and sizes as                   recommended by laminate flooring manufacturer for substrate and application method specified.

.06 Sealant: This is required to seal gaps around flooring edges, metal door frames, and in areas where moisture is present such as the expansion gap under kitchen stoves,                   fridges, dishwashers, etc. A clear silicone type or other type as recommended by laminate flooring manufacturer is used.

.07 Sealer: Some laminate manufacturers require that the cut ends of planks and tiles be sealed using a sealer material they recommend to prevent moisture absorption of the "raw"       exposed core.

.08 Touch-Up: This filler / dye / stain material is used to "hide" minor scratches in laminate flooring and must be as recommended, supplied and/or pre-approved by laminate flooring       supplier.

4 • LAMINATE FLOORING MOULDING, TRIMS, AND ACCESSORIES

.01 Various mouldings and trims are used in conjunction with laminate flooring: Such mouldings are used to cover the interface of laminate flooring with other flooring materials, and at perimeter and field expansion gaps.

T-Strip Mouldings: used in doorways / thresholds, and at changes in direction of laminate flooring. These mouldings cover the gap and allow for flooring expansion. Material may be laminate wrapped wood, extruded bronze or aluminum in continuous long lengths to suit requirements.

Reducer / Transition Strips: used to make a transition from laminate flooring to another flooring type that may be higher (thicker) or lower (thinner) than laminate flooring. Material may be a laminate wrapped material or extruded bronze or aluminum with widths and sizes to suit requirements.

End Caps / Thresholds: extruded bronze or aluminum used at end of laminate flooring at exterior doorways.

Wall Base: used to protect wall and other vertical interfaces. Material may be laminate wrapped material (e.g. MDF) or solid wood stained to match the laminate (for wood grain flooring), or painted wood with thickness and height as selected by the designer or Owner. In some case a coved resilient (rubber or vinyl) base may be suitable if the toe is sufficient to hide the expansion gap.

Base Shoe or Quarter Round: used on vertical face of bases to complete expansion void coverage when base is not thick enough to cover the expansion gap. Material is cut from one quarter of a full round of matching material as base and usually 13 mm (1/2") to 25 mm (1") in size and like wall base may be a laminate wrapped material (e.g. MDF) or solid wood stained to match laminate (for wood grain flooring), or painted wood.

Floor Vents and Grilles: these are fixed or adjustable, prefinished metal (although wood is also available) floor grilles for hot and cold air circulation complete with flange and are usually supplied by the mechanical trade or Owner.

.02 Installation: Method and materials to suit design requirements, flooring manufacturer's recommendations, and laminate flooring manufacturers details, using concealed or surface type fasteners and/or adhesive in accordance with design requirements.

5 • LAMINATE FLOORING DELIVERY, STORAGE, AND HANDLING

.01 Refer to E04B - Installation Guide for requirements.

6 • LAMINATE FLOORING INSTALLATION

.01 Refer to E04B - Installation Guide for requirements.