FABRICA Residential Stretch Over Cushion Instructions

FABRICA Residential Stretch Over Cushion

Product Information

Carpet Stretch over Cushion Instructions

This product is a carpet that is designed to be installed over a cushion. It is manufactured to rigid quality standards, and certain tolerances are considered within normal limits. The product is not covered by warranties if it has been cut and installed with visible manufacturing defects.

Before starting installation, inspect the product for concealed damage, manufacturing defects, and shipping errors. If you have any questions about the installation process, refer to Fabrica’s Technical Services Center or the CRI-105 reference guide for residential textile floor covering materials.

It is important to properly condition the carpet before installation to allow for sufficient stretch and avoid wrinkling. The job site conditions must be appropriate, including temperature, relative humidity, and cured concrete or wood floors. The cushion must be properly selected and adhered with pad cement or staples.

A comprehensive seaming diagram must be submitted and approved by the purchasing parties prior to installation. The seams should run lengthwise in major areas, parallel to traffic paths, into natural and artificial light sources, and be avoided at major pivot points where they may intersect perpendicular to doorways and entrances. For best results, Fabrica recommends installing its carpet in roll sequence.

Product Usage Instructions

Carpet Stretch over Cushion

1. Inspect the product for concealed damage, manufacturing defects, and shipping errors before starting installation.
2. Condition the carpet at least 24 hours prior to installation by rolling it out on the job site and smoothing out wrinkles.
3. Ensure that the job site conditions are appropriate, including temperature, relative humidity, and cured concrete or wood floors.
4. Select an appropriate cushion and adhere it with pad cement or staples. Install the cushion so that its seams are perpendicular to the carpet seams.
5. Submit a comprehensive seaming diagram for approval prior to installation.
6. Install the carpet in roll sequence, checking pattern lengths prior to making cuts. Arrange the cuts so that the longest patterns are installed first. Plan your work so that you can stretch the shorter patterns to match the longer ones if necessary. For solid colored textural patterns, follow the roll dye lot sequence.

For additional information or questions about the installation process, refer to Fabrica’s Technical Services Center or the CRI-105 reference guide for residential textile floor covering materials.

Attention: Before you start, read this bulletin and other applicable literature pertaining to the installation of Fabrica carpet. Any topics not specifically covered in this bulletin should be directed to Fabrica’s Technical Services Center at: 1-800-633-0468. For additional information, refer to the CRI-105, which is the standard reference guide for Residential textile Floorcovering materials.
Before starting installation inspect for: Concealed damage, Manufacturing defects and Shipping errors (example: wrong color, style, etc.)
Warranties from Fabrica specifically exclude claims involving carpet, which has been cut and installed with visible manufacturing defects.
NOTE: Should other trades perform work in areas where Fabrica carpet has been installed, the installer and / or general contractor assumes total liability for damage and deterioration, including wear, compaction, soiling, staining, abrasion, and stretching. Failure to provide adequate protection until occupancy may void all Fabrica Contract Warranties.
TOLERANCES: Fabrica products are manufactured to rigid quality standards. Because carpet is a textile product, certain tolerances are considered within normal limits and are not considered manufacturing defects.

CARPET CONDITIONING: A least 24 hours prior to installation, roll out carpet on the job site and smooth out wrinkles. Conditioning allows the carpet to relax and become more pliable for seaming and stretching for pattern match. NOTE: Failure to properly condition the carpet will not allow for a sufficient stretch, which may lead to wrinkling.

JOB SITE CONDITIONS

• TEMPERATURE: Minimum 65 F, 48 to 72 hours Prior to, during and after installation.
• WOOD FLOORS: Should have a minimum of 18” ventilated air space between the underside of the floor joists and the ground.
• RELATIVE HUMIDITY: Between 12 % and 65 %.
• CONCRETE: Cured for 90 to 120 days, must be sealed.
• CUSHION: Inappropriate cushion selections may result in wrinkling, and accelerated loss of appearance retention.
• Synthetic Hair / Jute:
  • 28 oz. per yard minimum weight light traffic, 3/8” maximum thickness.
  • 40 oz. per yard minimum weight heavy traffic, 3/8” maximum thickness.
• Slab Rubber: 80 oz. minimum weight, 3/8” maximum thickness.
• Rebond: 8 lb. minimum density for moderate to heavy traffic, 6-pound light traffic, 3/8” maximum thickness.

Install cushion so that its seams are perpendicular to the carpet seams. The cushion must be properly adhered with pad cement or staples.

• SEAMS: A comprehensive seaming diagram must be submitted and approved by the purchasing parties prior to installation. NOTE: The seams should run lengthwise in major areas, parallel to traffic paths, into natural and artificial light sources, and be avoided at major pivot points where they may intersect perpendicular to doorways and entrances.
• Roll Sequence: for best results, Fabrica recommends installing its carpet in roll sequence. Check pattern lengths prior to making cuts. Arrange the cuts so that the longest patterns are installed first. Plan your work so that you can stretch the shorter patterns to match the longer ones if necessary. For solid colored textural patterns, the roll dye lot sequence must be followed.
• Pattern Matching: Dry lay all pieces prior to starting the hot melt tape application. This allows for potentially relocating some pieces for a more acceptable match. PRE-STRETCH breadths prior to seaming. This will allow for closer matches and less stretching.
• Seam Cutting: Fabrica does not guarantee invisible seams; however, excellent seaming is achievable when following these procedures.

1. Using a straight bit screwdriver, awl or knitting needle, open up the tufted rows.
2. Use a loop pile or cushion back cutter and follow the opened row and keep the blade opposite to the selvage edge.
3. Head Seams: except under the most difficult situations, row cutting works well for head seams. Use of a seam stretcher or”crab” is also helpful for closing head seams.

• Seam Tape: Fabrica recommends the use of 3” wide medium-grade seaming tape. Six inch wide tape or tapes with extra hot melt do not add integrity to the seam and may telegraph their shapes through the carpet face. Use specialty tape for low profile products to reduce telegraphing and peaking along the primary backing.

SEAM MANUFACTURE

• Seam Sealer: For hot melt seams, use latex or an acrylic-based seam sealer. Apply a 1/8” bead of seam sealer to both sides of the seam and allow to sufficiently dry before applying the hot melt tape. This applies for both loop pile and cut pile carpets.
• Seam Board: Always manufacture the seam over a hard surface. Failure to do so will likely lead to an unlevel seam with an unacceptable appearance. A seaming board works well for this. A seaming board is typically 8” to 10” wide and 3½’ to 4’ in length and made of 3/8” thick plywood, with a slot cut out at one end to slide the unbonded seam tape.
• Seaming Iron: Set the thermostat for the iron between 2½ and 3. Increasing the temperature of the iron in an effort to speed seaming will only result in damage to the carpet back or face and a lower quality seam.
• Seaming: Use a flat carpet tractor to press carpet backing into hot thermoplastic. Spike tractors may damage the carpet fibers. Use a weighted piece of wood or non-conductive material of about 2 feet in length to pull behind the seaming iron. This will aid in heat dissipation and allow for more uniform cooling. DO NOT USE METAL, such as a toolbox tray. This will trap heat and compromise the integrity and/or color of the seam.
  Using a two head power stretcher or a “dead man”, stretch the shorter patterns to match the longer ones. Use stay nails to hold the stretched side on pattern and use a knee kicker to close gaps or push any fullness toward the center of the carpet. Leave stay nails in place until the hot melt tape has completely cooled.
  Complete the installation by obtaining a 1% to 1½% stretch in the length and snug tight in the width of the carpet. A power stretcher must be used. Knee kickers are positioning tools and lack sufficient force for stretching. Over stretching the carpet in the width will increase the probability of seam peaking.
  (see bulletin # 104, Seam Peaking) Specific questions not contained within this bulletin contact Fabrica Technical Services at 800-633-0468.

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