I wrote the installation and carpet evaluation reports on a large project on which I’m working involving 230,000- sq. ft. of material. We spent a great deal of time determining how to work with the product, how to prepare the floors, as well as other key issues. All of this was submitted, addressed, agreed upon and assumed to be communicated to all parties to whom it was pertinent.

When I went to check on the job, the carpet was, for the most part, straight; however, some pattern distortions and waver existed which, despite making me unhappy, will be pretty much covered with furniture. We voiced our displeasure to the manufacturer’s rep and notified him that if the product presented an extraordinary challenge to the installers on the job, the mill would be responsible for the extra labor.

STEP OVER STITCH

The installers were using power stretchers, a dead man, knee kickers, row cutting, and sealing the seams. However, they weren’t told or shown any of the information in the report which was imperative to properly installing the carpet.

One product, which has a graphics pattern, step over stitch, high ribbed back with an attached secondary backing, had a space between the gaps in the ribs and the backing. In other words, the backing was not attached to the backing between the ribs. This physical characteristic required sealing the cut edges of the carpet with latex seam sealer first to insure the backing did not delaminate when the carpet was put into use. There was no latex seam sealer on the job; solvent- based seam sealer being used on the seams.

ROBERTS MINI STRETCHER

The installers were also working much harder than they had to aligning the product with a power stretcher, dead man and knee kickers instead of a Roberts mini stretcher. They were wrestling with heavy rolls of carpet and dragging the product up or down to position it.

DEAD MAN

This back breaking work could have been eliminated by using specialty handling equipment available from the likes of National Carpet Equipment, Gundlach or other suppliers. The installers were also not using rollers to roll the carpet after installation. Instead, they would just lay the carpet in and come back the next day to tend to bubbles with a carpet tractor. This made for much more work and time spent than was necessary.

INSTALLATION INSTRUCTIONS

Until I arrived to meet with the installers, showed them what was supposed to be done and why and told them about the equipment which should have been available to them, they had no idea there was any report with installation instructions. Now, wouldn’t you think the information should be shared with them?

SEAM SEALIN

First, as union contractors out of a major installation firm, a member of a large organization, I was surprised they didn’t have the tools they needed on the job to make it easier. It was also surprising that there wasn’t at least a roller on the job. This device is a given on a direct glue down installation.

The other issue we had was the preparation of the substrate. It had been leveled, tested and prepared properly but it was not being cleaned correctly. Since part of the glue being used was a from a spray system it is imperative no dirt be mixed with the adhesive to compromise it. This type of adhesive goes on much thinner, is more viscous and can be compromised by dirt residue not removed from the substrate.
After all parties involved met, there was an understanding as to what had to be done, why and what the consequences would be if the instructions were not followed. By actually going to the job site, working with the installers, the general contractor, installation contractor, job site supervisor and carpet mill, we can insure the installation is done by the book.

This simplifies the installation process and minimizes or eliminates problems. With the right tools and an open line of communication, there would be far fewer claims in the industry. Do you need help with this type of project of something similar? Let me know, I’d be happy to work with you.