S I T E - R E L AT E D S O L U T I O N S
NEW CONSTRUCTION
Q:
A:
How do I choose the right installation solution
for my next modular carpet project?
A wide range of factors will determine the installation solution best
suited to a particular site. On grade or above? How quickly does
installation need to begin? Are there moisture concerns? Milliken
has the answers. To find the right solution for your situation,
just turn the page.
SITE-RELATED SOLUTIONS
FOR NEW CONSTRUCTION
With new construction, installing
carpet tile can feel like a no-win situation.
Moisture is the X-factor.
A newly poured four-inch concrete slab takes four to five
months to be fully ready to accept flooring — and that’s
under ideal conditions. To nobody’s surprise, construction
schedules rarely allow for that amount of time. So — do you
extend your timeline? Spend more for concrete admixtures
or third-party moisture-mitigation solutions? None of
these solutions is ideal. Meanwhile, there might be some
unexpected problems lurking under your carpet.
Rising moisture vapor is trying to escape.
The worst thing to do is try and stop it.
Obstructing a natural process simply gives rise to another natural process.
If an impenetrable barrier gets in the way of escaping water vapor, condensation
is what you get. That isn’t good when it happens under your carpet. Water droplets
begin to form along the bottom of the backing, eventually creating liquid water
between the concrete and the floor covering.
Hardback carpet does not allow water vapor to vent. It’s a precise definition
of “impenetrable barrier.” Condensation will occur. The most common solution?
To hide it. To literally sweep it under the rug. That’s where the real trouble starts.
Concrete with hardback floor covering
Uncovered concrete
Water vapor travels freely through open concrete and
vents naturally, evaporating into the atmosphere
Trapped water will lead to increased alkalinity — elevated pH
which will cause the adhesives to fail and also create a potential
breeding ground for mold and mildew under your floor covering
Water can cause all kinds of problems.
Here’s a very basic science lesson: As part of a larger
ecosystem, buildings are continually subject to fundamental physical
processes. Such as this one: Moisture seeks equilibrium. It essentially
just wants to evaporate. Water vapor will naturally rise until something
gets in its way. Concrete is filled with vertical capillaries and does
not hinder the process.
Reactions between water and concrete can lead to increased
alkalinity, as well as possible staining from efflorescence. Water
can also cause adhesives to re-emulsify and become viscous —
your glue basically turns to jelly. That’s not an effective adhesive.
Worst of all, dark, wet spaces lead to mold and mildew. In some
cases this can create health concerns, migrate to other building
systems like HVAC, and affect indoor air quality. The formation of
water is how unseen problems can become worst-case scenarios —
very, very expensive to mitigate.
SITE-RELATED SOLUTIONS
FOR NEW CONSTRUCTION
All Milliken modular carpet products have been
designed to manage moisture simply and effectively:
We let natural processes happen naturally.
Milliken Modular Carpet
Tufted Face Fiber
Primary Backing
Moisture Barrier
Moisture on top stays on top,
vapor stays below
Unlike with hardback products, water vapor has a way to escape
from beneath Milliken’s cushion backing. It travels freely through
our open-cell cushion, until evaporating naturally through seams
at the edges of each carpet tile.
Open-Cell Cushion
Vapor moves easily through
to vent at seams
Nonwoven Felt
Allows vapor from the subfloor
to pass into open-cell cushion
Vapor penetrates into Milliken open-cell cushion,
is wicked to seams and vents naturally
Milliken installation solutions do not require moisture testing.
Our unique cushion backing and its moisture vapor-wicking properties allow
Milliken modular carpet to handle concrete with higher relative humidities
than other products. Provided our timing guidelines are followed, our
products have no pH or RH limits. Nor does Milliken require moisture
testing prior to installation.
Condensation will not occur with Milliken. In combination with
our Non-Reactive Standard and Moisture Extreme adhesives, Milliken cushionbacked modular carpet allows moisture vapor to evaporate at a very high
rate, so the formation of liquid water is almost impossible. Expensive and
time-consuming moisture-based failures are therefore virtually eliminated.
Milliken stands behind all of our cushion-backed
modular carpet products with a lifetime warranty against
adhesive breakdown due to moisture vapor emissions.
What’s more, the relationship between various parties —
manufacturers, contractors, adhesive suppliers — can often
lead to very sticky liability issues. Where does the responsibility
actually fall? Milliken’s warranty provides our customers with
a single point of contact to deal with any liability concerns.
How can we offer this? The answer is simple: When moisture
vapor becomes water, that’s where the problems start. With
Milliken cushion-backed carpet, moisture vapor simply evaporates.
SITE-RELATED SOLUTIONS
FOR NEW CONSTRUCTION
Milliken requires that all new concrete pours
comply with ACI 302 – 2001 guidelines.
It doesn’t matter whether you’re
on grade or above grade.
Remember, in ideal conditions, it takes a four-inch concrete slab four to five
months to be fully ready to accept flooring. So, what’s the best way to assure
that retained moisture doesn’t create any future headaches?
Milliken modular carpet is a moisture
mitigation solution all by itself.
No moisture testing. Fully warrantied.
On grade or above grade, standard Milliken cushion-backed modular
carpet, in combination with our Non-Reactive Standard adhesive can
be installed as soon as 90 days following a new pour with no moisture
testing. There are no RH or pH limits. Both carpet and adhesive are
fully warrantied under virtually every circumstance.
The use of standard Milliken cushion-backed modular carpet,
together with our Non-Reactive Standard adhesive:
Prevents the possibility of moisture-related issues from
occurring — under virtually every circumstance.
Moisture mitigation is built directly into every standard
Milliken carpet tile — it is an inherent property of the
cushion backing itself.
Installation of Milliken modular carpet can begin as quickly
as 90 days after the new pour is complete.
Need to install in less than 90 days?
Switching to Milliken Moisture Extreme adhesive makes it possible to
install our standard cushion-backed carpet tile in as little as 45 days
following a completed pour, or in situations with more severe moisture
concerns. Carpet and adhesive are fully warrantied, there are no RH or
pH limits, and no moisture testing is required.
FAQs
SITE-RELATED SOLUTIONS / NEW CONSTRUCTION
Why has moisture become
such an issue now?
1
Because of current trends that favor modular
carpet over broadloom. Broadloom handled
retained moisture in concrete similarly to
Milliken cushion backing, in that it let vapor
pass through and evaporate naturally. Modular
carpet, however, requires a more stable backing
than does broadloom in order to maintain its
integrity. It turns out that hardback carpet tiles
happen to be just about the perfect way to
block water vapor from venting.
2
What’s all this talk about
alkalinity and pH?
Most carpet adhesives are rated for pHs of
around 9 and everything works well as long as
no liquid water is present. However, elevated pH
becomes a major concern once liquid water enters
the equation. Liquid water will activate the Alkaline
salts, inherent in all cement, which will increase the
pH level at the surface of a concrete slab. Flooring
failures occur when the adhesive is exposed to
sustained, moist, high pH environments. This is
why warranties often have language that will void
them at higher pHs. Milliken cushion-backed
modular carpet allows moisture vapor to evaporate
at a very high rate, eliminating the formation of liquid
water. No water – no problem, hence our ability to
eliminate the need for pH testing and limits.
3
What’s the big deal about
moisture testing, anyway?
It can be expensive, and there are limits to its
accuracy. As to the expense issue, your final bill
will depend on how many tests are required over
how large an area. More importantly, a moisture
test is only a snapshot in time. Moisture levels rise
and fall naturally, in some cases wildly so. Though
declared safe at installation, levels may no longer be
safe after an issue occurs — which is exactly when
crucial warranty-related testing will be required.
Put simply, your warranty may be in jeopardy.
4
What about this bond test?
You said no testing.
That’s a fair question. But here’s the thing —
adhesives have to stick to the subfloor. Moisture
occasionally causes adhesion problems. More often,
issues arise from chemical incompatibilities between
adhesives and topical treatments or admixtures
that may be present in the concrete — and these
are invisible to the naked eye. A bond test confirms
that adhesives will maintain their integrity. As long
as the adhesive will work, you’re good to go.
THERE ARE VERY FEW CONDITIONS — For Milliken installation solutions, we ask that a few conditions be met. They are:
a) There is no visible water
b) All new pours require the use of an ASTM E-1745 vapor retarder (Class B minimum) placed in accordance with
ACI 302–2001 and directly in contact with the concrete placement.
c) Floor prep must be performed in accordance with ASTM F 710-11, except where explicitly allowed by this document
and/or installation instructions.
d) All topical curing compounds must be removed prior to application of adhesive.
e) Existing adhesive must be removed when using Moisture Extreme Spray Adhesive on or below grade.
f) Bond test required
HYDROSTATIC PRESSURE (on-grade only) — We should note that Milliken does not warrant against hydrostatic pressure,
instances where water is forcibly pushed into the slab and/or moisture events caused by broken pipes. In such cases the
warranty will be voided. If you’d call that fine print, we won’t argue — but we think you’ll agree that’s a pretty fair stipulation.
Customer Concierge 800.824.2246 | millikenfloors.com
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