syndigo Procore Plus Surfaces Instruction Manual
- June 5, 2024
- syndigo
Table of Contents
syndigo Procore Plus Surfaces
PROCORE® PLUS INSTALLATION INSTRUCTIONS
Quick Reference:
- Concrete moisture requirement: For all on and below grade concrete, use a 6-mil (0.006-in.) Polyehtylene (PE) sheet or equivelent
- Flatness tolerance: < 1/8-in. over 6-ft. and 1/16-in. over 1-ft. in all directions
- Installation temperature: Between 60°F to 80°F (16°C to 27°C)
- Optimal service temperature: Between 40°F to 90°F (4°C to 32°C)
- Additional acoustic underlayment: Not required or recommended
- Expansion gap (entire perimeter): 1/4-in. ≤ 50-ft., and 1/2-in. between 50 – 85-ft. lengths or widths
- Expansion joints (large areas): Only required if > 85-ft. in length or width
- 3-IN-1 doorway transition: Not usually required
- 3-Season rooms: Acceptable (but see “Expansion Gap”)
- Pet stain warranty: Yes, but immediately clean up when discovered
General Information & Limitations: Please watch the installation videos available at Lowes.com. This flooring has a high-density core (HDC), designed to be installed indoors only, as a “floating floor” for residential applications. The optimal operating temperature is between 40°F to 90°F (4°C to 32°C). Avoid prolonged exposure to direct sunlight or other heat sources where temperatures will exceed 90°F (32°C), as damage may occur. This product is not suitable for heavy rolling loads. Rolling chairs with soft or W-type casters and a maximum rolling weight of 250 lbs. are acceptable, provided that a polycarbonate chair mat is used to protect the flooring in rolling chair areas. Do not secure flooring or furniture to the subfloor with mechanical fasteners or adhesives. Do not install cabinets, kitchen islands, or other non-movable furniture on top of this floor covering. Contact the technical department at 1-888-509-3438 or techsupport@novalis-intl.com for assistance. Copies of ASTM documents are available for purchase at www.astm.org.
Recommended Tool List: Appropriate Personal Protective Equipment (PPE) including safety glasses, gloves and suitable dust mask. Appropriate tools to prepare the substrate, Hepa filtered vacuum, 6-ft. and 1-ft. straight edge or level, two quarters (U.S. coins), tape measure, pencil, speed square, utility knife with blades, 1-lb. (∼ 16-oz.) rubber or soft faced dead blow hammer (preferred) or rubber mallet, chalk-line, pull-bar, Oscillating Multi-Tool or hand saw (door jambs), wedge spacers or similar, jigsaw with carbide blades, knee pads. If required, use a super-glue liquid adhesive for any small pieces.
Warning: All local, state, and federal regulations must be followed;
this includes the removal of in-place asbestos (floor covering and adhesive)
and any lead-containing material. The Occupational Safety and Health
Administration (OSHA) has exposure limits for people exposed to respirable
crystalline silica; this requirement must be followed. Do not use solvent or
citrus-based adhesive removers. When appropriate, follow the Resilient Floor
Covering Institute’s (RFCI) Recommended Work Practice for Removal of Existing
Floor Covering and Adhesive. Always wear safety glasses and use respiratory
protection or other safeguards to avoid inhaling any dust. The label,
installation, and maintenance instructions along with the technical data
sheet, limited warranty and any appropriate Safety Data Sheet (SDS) of all
products must be read, understood, and followed before installation commences.
If the substrate or subfloor fails for any reason, then the floor covering
limited warranty is void.
Do not leave spills unattended – wipe up promptly, and allow the floor
covering to dry before trafficking. Use bathmats and install safety handrails
where this floor covering is used next to wet or barefoot areas, like showers
and baths.
Documentation: Record and file the measured and observed site
conditions and test results, including all photographs and corrective
measures. Maintaining this documentation, along with the original invoice and
any labor receipts throughout the warranty period, is recommended, as this
will be required in the unlikely event of a claim.
Site Conditions: The prepared installation area must be fully enclosed and
weather tight. During the installation, any direct sunlight should be blocked
using blinds, drapes or other protection. The ambient temperature during
installation must be > 60°F (16°C), with a recommended maximum of 80°F (27°C).
Note: When installing at temperatures > 80°F (27°C), the size of an
expansion gap will increase when the floor covering is cooled.
Flatness: Check all substrates for flatness prior to installation. The maximum acceptable tolerance is < 1/8-in. gap (2 x US quarters) over 6-ft. and ≤ 1/16-in. gap (1 x US quarter) over 1-ft. Make any necessary adjustments to the substrate before installation. Dormant cracks, saw cut joints and grout lines < 1/8-in. wide or deep are acceptable – all others must be cleaned of all dirt and debris, then filled using a suitable commercial grade patching or repair compound, following the product instructions.
Concrete Subfloors: All concrete must be free of contaminates and structurally sound. If required, smooth the surface using a suitable, moisture-resistant commercial grade leveling or patching compound, following the product instructions. Do not install if hydrostatic pressure is visible, present or suspected. If a chemical adhesive remover has been used, contact the technical department.
For all on and below grade concrete slabs, test the surface to confirm it is absorbent (porous), following the ASTM F3191 Standard Practice for Field Determination of Substrate Water Absorption (Porosity) for Substrates to Receive Resilient Flooring. The water droplets placed on the substrate must be absorbed for it to be considered absorbent. If required, the concrete can be made porous by mechanical methods, such as diamond grinding, a DiamaBrush buffer attachment, shotblasting or similar.
Concrete Moisture: For all on and below grade concrete slabs, use a ≥ 6-mil thick polyethylene (PE) sheet, available at Lowe’s. Sheeting must be installed over the entire area and extend at least 2-in. up the walls. All seams must be overlapped and taped according to the product instructions. The liability and warranty for any product’s performance remains with its manufacturer.
Wood Subfloors: All wooden subfloors and substrates must be dry and in
compliance with the moisture content percent (MC-%) for your region. Regional
values are freely available by searching “moisture map of wood” images. Test
using a non-destructive electronic moisture meter, following the product
instructions.
The subfloor must comply with local building codes, have at least 18-in. of
well-ventilated air space below and have a suitable vapor retarder to isolate
the subfloor from ground cover and outdoor conditions. Wood subfloors must
have a total thickness of at least 1-in. Sleepers must not make direct contact
with concrete or earth. If necessary, install an underlayment grade plywood
with a minimum thickness of 1/4-in. on the surface. The underlayment must be
installed in the opposite direction to the subfloor, following ASTM F1482
Standard Practice for Installation and Preparation of Panel Type Underlayments
to Receive Resilient Flooring.
Note: plywood is a water-sensitive subfloor that may become damaged or
deformed by topical liquids. To protect wood subfloors from topical water
exposure, follow the Wet Area Guidelines below.
Additional Acoustic Underlayments: Additional acoustic underlayments are not recommended or required. However, should one be used, ensure a polycarbonate chair mat is used in all rolling chair areas. Do not use additional acoustic underlayments in any commercial areas.
Unsuitable Subfloors: These include but are not limited to: any floating
or loose floor coverings, hardwood, carpet, cushion vinyl, rubber, cork, foam,
asphalt tile, any additional acoustic underlayment, any substrate with visible
mold, mildew, or fungi and any substrate in wet areas, such as inside showers
and saunas. Do not install directly over any adhesive or adhesive residue of
any kind. Do not install directly over radiant heated substrate or in
recreation vehicles, campers or boats.
Note: Existing hardwood floor coverings will swell when exposed to
moisture: vinyl floor covering may restrict the movement of moisture in
hardwood, which may result in flooring failure, especially when installed on
or below grade. Some hardwood floor coverings may also discolor vinyl floor
covering, which is excluded from warranty coverage. By electing to install
over any existing floor covering releases the manufacturer from any
responsibility regarding the suitability and continued performance of that
product, including any resulting effect on the new floor covering, such as
indentations and damaged locking mechanisms.
Other Subfloors/Substrates: These may be acceptable. However, they must be
and remain dry, without contaminates and be structurally sound.
Wet Area Requirements: Some subfloors, such as plywood, may be sensitive to and damaged or deformed by topical liquids, such as water, pet urine and spills. While ProCore Plus is a waterproof product, water-sensitive subfloors may require additional protection to prevent water exposure. When installing floor covering in wet areas, ensure that bathmats or similar are used where appropriate to decrease the amount of water that can collect on the surface. Any and all spills should be cleaned up immediately after discovering them and within 8 hours. Subfloor flatness is critical to preventing water migration through seams that may flex or peak due to foot traffic and subfloor deflection – be sure to check flatness and make all necessary adjustments prior to installing.
Water-sensitive substrate must have a ≥ 6-mil thick polyethylene (PE) sheet (available at Lowe’s) installed over the entire area and extend at least 2-in. up the walls. All seams must be overlapped and taped according to the product instructions. In addition, the area must be separated from all other rooms using a suitable water-resistant t-molding. Following flooring installation, the plastic sheet must be trimmed flush with the surface of the subfloor. Prior to installing wall-base or molding, the required perimeter expansion gap must be filled with a 100% silicone caulk, including the wet area side of all t-moldings. Additionally, all door jambs, plumbing and vertical surfaces that won’t have wall-base or molding installed must be sealed with 100% silicone caulk. Once the entire perimeter has been filled or sealed, water-resistant wall-base, moldings or other accessories may be installed. Apply a bead of silicone caulk to the parts of the wall-base or moldings that will make contact with the surface of the flooring. Ensure all wall base and moldings are attached to the subfloor, wall or wall-base without compression, to allow movement and cleanup any remaining silicone immediately. Do not anchor wall- base or moldings into or through the floor covering.
Expansion Gap: If the length or width of the installation area is ≤
50-ft., an expansion gap of at least 1/4-in. must be created around the entire
perimeter. If the overall length or width is between 50 – 85-ft., then the gap
must be increased to 1/2-in. around the entire perimeter. A maximum of 85-ft.
in length or width must not be exceeded. If required, use a suitable trim
molding covering the edges by 1/8-in. and allowing a 1/2-in. expansion gap.
For three-season rooms, a gap of at least 1/2-in. around the entire perimeter
is required. In addition, the area must be separated from all other rooms
using a suitable trim molding. The maximum of 30-ft. in length or width must
not be exceeded.
Note: Areas with very heavy furniture ≥ 800-lb. (363-kg) must be isolated
from the rest of the installation with a compatible t-molding and have ≥
1/2-in. expansion gap.
General Preparation: It is recommended to remove all wall-base before
flooring installation. Alternately, a quarter round molding (fixed to the wall
or wall-base only) that covers both the required expansion gap and at least
1/8-in. of the floor covering may be installed. Undercut all wooden door jambs
and the first in. of any remaining wall-base (later covered with molding) with
an Oscillating Multi-Tool or hand saw – the height must be the thickness of
the floor covering plus 1/64-in., which allows the floor covering to expand
and contract freely, out of sight, with temperature fluctuations (see figure
1). Steel door jambs should be pattern-scribed, leaving the required expansion
gap. Use a color-coordinated 100% silicone to fill the void. Clean the entire
area to be installed using a HEPA-filtered vacuum.
Before beginning, check and make sure the lot numbers on the packaging match
and mix the floor covering from several boxes to ensure a random appearance.
During the installation, inspect for visible defects, including any damage,
gloss, color or shade variations, dirt and debris in the locking mechanism
(remove using a soft brush), as installing it assumes full responsibility. If
you have any concerns, do not install and immediately contact the technical
department.
Layout: Follow the design or drawings provided or agreed upon by the designer, architect, or end-user. The end joint layout for all planks should be random – make sure joints are not “stair stepped”. Failure to randomize end joints could weaken the integrity of the joint system, which may lead to failure. All planks must be at least 8-in. in length and all end seams must staggered by ≥ 8-in. Tiles must be installed in a brick-bond pattern, offset by 1/2 or 1/3 of the plank.
Cutting: To cut the floor covering, measure and mark the surface with a pencil, then carefully score the surface a few times on the mark using a sharp utility knife along the side of a speed square (see figure 2). Snap the plank downwards and complete by cutting the backing from underneath (see figure 3). For complicated cuts, such as door jambs, it is recommended to use a jigsaw with a carbide blade following the product safety instructions.
Installation: Clean the entire area to be installed twice using a HEPA- filtered vacuum. Determine the best wall to start installation on – typically this would be the longest straight wall with a doorway (if present). Measure the width of the room and, allowing for two expansion gaps, calculate the width of your last row. If it is less than half the width of the floor covering, or if a balanced design is required, than reduce the width of the first row accordingly. Use a chalk-line to mark the outside edge of the first row on the substrate. If needed, trim the first row (the side without the extended locking mechanism) to fit, accounting for the expansion gap (see figure 2).
First Row (slide): At the left corner of the starting wall, position the first tile or plank flush with the walls. Use the side and end without the extended locking mechanism against the walls. Place wedge spacers between the floor covering and wall to maintain the required expansion gap around the entire perimeter (see figure 4). Before connecting the second piece, lay it flat on the substrate, adjacent to the first row and lined up with the end of the previous piece. Then, while keeping the joint perfectly in line, slide the second plank into the first, locking the mechanism together (see figure 5). Complete the first row using this method. If there is a doorway, measure, mark and cut the flooring to make sure the cut edge will be located underneath the door jamb and frame while maintaining the required expansion gap. A jigsaw should be used for complicated cuts like these. Keeping the installation straight is critical, so check the first row using a chalk line or similar and, as needed, adjust and reinforce the row by adding more wedge spacers. The acceptable straightness tolerance is within 1/16-in. for lengths over 20-ft. or 1/32 in. for lengths under 20-ft. Complete the following rows starting with a cut piece, such as a piece from a previous row. Install the side joints before the end joints as instructed under “Side Joints” and “End Joints”.
Side Joints (angle-angle): Starting at the left corner, place the side
without the extended locking mechanism into the side of the previously
installed row at a ∼ 25° angle (see figure 6). Make sure the joint is seated
properly, then slide the plank or tile into position (see figure 7). The end
joint must line up perfectly. Lay the tile or plank flat and complete the end
joint.
End Joints (drop-lock): Always check the alignment of the end joint and adjust
if necessary. Lock the joint into place by lightly tap along the high side,
starting from the “T”, using a 1-lb. (∼ 16-oz.) soft faced dead blow hammer or
rubber mallet (see figure 8). Keep the striking head flat with the floor
covering and tap until perfectly flush. If the locking mechanism does not line
up properly, then check and adjust the straightness as necessary.
Pro-Tips: Do not hit the locking mechanism directly with any hammer,
tapping block or pull bar (except the last row) – doing so will damage the
locking mechanism and may result in peaking, gapping or broken joints. If
required, use a ∼ 6-in. piece of scrap floor covering, seated in the locking
mechanism, to lightly tap and close any joints.
If you need to install small cuts of floor covering that are < 3-in. in length
or width, place a thin bead of liquid super-glue on the previously installed
locking mechanism just before installing. This will ensure the pieces remain
locked together during use. Do not get the adhesive on the surface – coverage
will be ∼ 30 ft. per oz.
After the first five or six rows are completed, turn around and continue
installing, working on top of the installed material. This will allow the side
joints to be pulled together rather than pushed together, which will make the
installation even easier.
If you need to disengage the end joints for any reason, first unlock the side
joints by lifting the outside edge of the row to ∼ 25° and disconnect the
entire row. Make sure all pieces are lying flat and are properly engaged (tap
to engage, if required), then simply slide them apart. If they are angled or
pulled upwards, the joint will break.
Completion: If used, plastic sheeting must be trimmed flush with the surface of the floor covering. If installed in a wet area, plastic sheeting must be trimmed flush with the subfloor. When installing in wet areas, ensure the expansion gap and all vertical surfaces are filled or sealed with a 100% silicone caulk and ensure all wall-base and moldings are water-resistant, following to the Wet Area Guidelines. Install all necessary wall-base and/or moldings and ensure they are anchored to the substrate, wall or wall-base without compression, to allow movement. Do not anchor wall-base or moldings into or through the floor covering.
Protection: If required, protect the clean floor covering from other trades or heavy loads using ½-in. plywood or similar and tape all seams. For light traffic, use Ram board or similar and tape all seams. For furniture, use only polyurethane, silicon or felt glides (replaced > 3-times a year), keeping them clean and grit-free – all glides should be ≥ 1-in.2, especially on heavy furniture. Use protective polycarbonate chair mats designed for resilient flooring underneath rolling chairs or soft “W-type” wheels. Use non-rubber- backed entrance matting at all outdoor entrances, as this will improve air quality and reduce maintenance. Do not drag heavy or sharp objects directly across the surface – use hard surface “sliders” (available at Lowe’s). For areas that may be subjected to standing water on the surface, such as bathrooms with a bath or shower, the perimeter of the installation must be properly sealed using a 100% silicon caulk to prevent water from getting beneath the flooring. To avoid excessive fading or discoloration from direct sunlight exposure, use appropriate window treatments, an effective UV/IR film or Low-E glass windows. Take photographs and have any required documentation signed and filed following completion.
PROCORE® 3-IN-1 TRIM MOLDING
General Information: If the overall length of the area is over 85-ft. in
either direction, if temperatures are expected to exceed 90°F (32°C), like in
3-season rooms, or if a transition is desired, a 3-In-1 trim molding should be
installed. 3-in-1 trim moldings are color-coordinated and available at Lowe’s.
Note: Colors and patterns that have a high color variance won’t match
perfectly.
INSTALLATION INSTRUCTION FIGURES
References
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