DuraFlex

Installation Guidelines

GENERAL INFORMATION

The DuraFlex Six-Foot Releasable Program is designed where access to the floor is required with fewer

seams compared to carpet tiles.The Duralon backing (attached cushion) is the only backing system

available for this program.

NuSpraylok™ adhesive is required for use with the DuraFlex program.The Mohawk Group and/or Durkan

Patterned Carpet are not liable for any product failure if proper floor preparation and/or installation

procedures are not followed. It is the responsibility of the installation contractor to make certain the floor

is properly prepared and suitable for the installation. Installers must be trained and certified by the

Mohawk Group for this type of installation.

NuSpraylok™ Plus (DK127) is required whenever the Moisture Vapor Emission is up to 7 lbs.

per 1,000 sq. ft. per 24 hours when tested with a pre-packaged Calcium Chloride crystal kit

performed in accordance with ASTM F 1869-98, and a pH of 11 when tested according to

industry standards.

NuSpraylok™ Plus Platinum (DK130) is required whenever the Moisture Vapor Emission is up

to 10 lbs. per 1,000 sq. ft. per 24 hours when tested with a pre-packaged Calcium Chloride

crystal kit performed in accordance with ASTM F 1869-98, and a pH of 12 when tested

according to industry standards.

NUSPRAYLOK™ CONDITIONS

For safe handling and storage information on this product, consult the Material Safety Data Sheets (MSDS).

DO NOT FREEZE – THAW STABLE. STORAGE MUST BE @ 65º F OR ABOVE.

• Perform required Moisture Vapor Emission and Alkalinity Tests. TESTING IS MANDATORY.

Test results must be on file in the Mohawk Group Field Services Dept. before the job starts.

• A Freeze Indicator is applied to the top of each cylinder, if the cylinder has been frozen, the

freeze indicator will pop out black or red. A Temperature Strip has also been applied to the

side of each cylinder, to determine the temperature.

• On replacement installations, whenever the moisture vapor emission is 5 or higher and the

pH is 10 or above, adhesive remover is required. Using NuSpraylok™ Adhesive Remover

(DK138) and following the procedures for its use will ensure that all the old adhesive will be

completely removed from the substrate, otherwise the NuSpraylok™ adhesive will not

bond to the concrete, but will bond to the old adhesive. If the moisture and pH levels rise

above the previously mentioned levels, old adhesive will re-emulsify and cause the

installation to fail.

DuraFlex

Installation Guidelines

FLOOR PREPARATION

The floor should have a minimum temperature of 65°F for at least 72 hours prior to installation and 48

hours after installation. Temperatures should not exceed 90°F.

Metal:Metal floors must be cleaned of any grease, dirt, or rust.

Terrazzo, Ceramic, Marble & Slate: All grout lines should be filled and leveled.

Concrete:Moisture Vapor Emission and Alkalinity tests are required. Concrete should be

clean, dry and free of any grease, oil, paint, dirt, old adhesive, or any other compounds that

may interfere with the bonding of the adhesive. All holes, cracks or other related floor

defects should be filled with a Portland based floor patch.

SITE CONDITIONS

Whenever possible, all of the carpet should be rolled out and acclimated to room temperature 24 hours

prior to installation.The temperature where the carpet is to be installed should be between 65º F and 95º F,

and the relative humidity should be between 10% and 65%. Floor temperature should be between 65º F,

and 85º F.

ROLL SEQUENCE FOR SIX-FOOT PROGRAM

Sequence numbers are placed on each roll.These numbers are in order from which they were printed, and

then trimmed. Following these procedures will minimize the pattern variation that must be dealt with

during the seaming process.

SEAM PREPARATION

After the printing process is complete Durkan’s Seaming Department splits the 12’ broadloom into six-foot

rolls. A cardboard disc is placed on the end of each roll to protect the cut edges.

• Two sets of installation instructions will be enclosed in the roll, which is wrapped in RED

PLASTIC, with INSTALLATION INSTRUCTIONS ENCLOSED printed in white letters.The

installation instructions include the seaming diagram, and the installation guidelines.The

seaming diagram will indicate the location of known seams. In some cases it may be

necessary for additional seams.

• Select the best location for the first seam and strike a chalk line on the floor square with the

walls for seam placement. No seam is invisible, therefore, when possible, place seams in

areas with least traffic, away from the direct lighting, and perpendicular to side lighting.

• The carpet must be adhered to the substrate with The Mohawk Group’s NuSpraylok™

adhesive.This adhesive will allow the carpet to be removed easily, yet strong enough to

hold the carpet in its proper position.

installation method installation method

CUTTING PROCEDURE

Locate an exact point in the pattern approximately 3/4” to 1” from the selvedge edge. Cut along

complementary patterns using a cushion back cutter and straight edge from the face.Trim with the blade

closest to the seam edge; hold the cutter slightly away from the seam edge at no more than a 5 degree

angle, as to cut slightly more backing material than face yarn.These procedures should be followed on

both sides of the seam.The pattern that is trimmed from one side must be left on the other. One half of the

seams will be precut at the mill. No additional trimming will be needed for the precut seams.

The precut seams must be sequenced as they were cut at the mill.

Durkan’s printed carpet is tufted, the secondary backing is applied, and then the carpet is printed. Printed

carpet does not follow tufting rows: therefore, running a row will not result in a pattern match.

SEALING THE CUT EDGES

After the edges are trimmed apply a latex seam sealer to both edges of the seams. The sealer should be

applied only to the primary and secondary backing. Avoid getting sealer on the face yarns. Allow the seam

sealer to dry before continuing to the next step.

DRY-LAY

After the carpet has been placed in its designated areas and the seams trimmed and sealed, dry lay all

breadths.The starting point will be the longest pattern-repeat section, gradually working down to the

shortest pattern repeat section. Align the pattern in the center of each breadth. Check the bow, pattern

elongation, and skew. If the pattern run-off is more than one half inch in twelve feet, pre-stretch the carpet

using a dead man and power stretchers. This procedure is performed before any adhesive is applied.

Stretch in ten to twelve feet increments at a time.

• When pre-stretching, over stretch the carpet as much as needed to ensure a proper match.

Example: If the pattern-repeat runs off one half of an inch, stretch the carpet one inch. After the

stretchers are removed, some of the stretch will slip back, but not the entire stretch. At this time,

the installer will be able to determine the amount of stretch the carpet will require to achieve the

pattern match after the adhesive has been applied.

• After the pattern has been dry laid, make sure that each section of carpet lines up to the reference

lines on the floor. Position the carpet so that the patterns are matched in the middle of each

breadth. Stay nails may be used to prevent carpet from shifting.

• Begin with the breadth that has longest pattern repeat.Very carefully fold the first two breadths

back three feet from the seam edge.

APPLYING ADHESIVE

Before applying any adhesive, be familiar with the NuSpraylok™ system. An Installation DVD is enclosed in

the Starter kit (DK119). Review this before spraying any adhesive. The heat jacket (DK138) should be

applied to the cylinder ten minutes before spraying adhesive. When the adhesive is warm it will spray a

uniform pattern.

installation method (cont...) installation method (cont...)

• On breadth’s over fifty feet, two people are required to spray the adhesive.When two technicians

are spraying, begin in the middle of the area where the carpet is folded back.

• Hold the wand approximately 18” to 25” off the floor at a 45 degree angle. Spray a heavy frost—

approximate coverage yield is 100 yards per cylinder.Walking slowly, spray a uniform pattern

overlapping the application half way.

• When applying adhesive next to walls, other flooring materials or around obstacles, hold wand

perpendicular to the floor and up approximately 8” off the floor.Move wand in a smooth and

continuous motion in one direction applying a 6” to 10” wide band of adhesive to the substrate.

The use of a spray shield is recommended when applying adhesive next to finished walls, etc. The

NuSpraylok™ 22 oz. cans may also be used in tight areas.

• Sufficient amount of adhesive must be applied to allow a 100% transfer of adhesive from the floor

to the carpet back. Immediately after spraying unfold the longest pattern section back into the

adhesive. Next, unfold the other section into the adhesive.

SEAMING

Start in the center of the seam, join the seam in both directions only as far as the match will allow.Using a

knee kicker and a mini stretcher, compress the two sections together.

• Use a carpet tractor or seam roller to blend the fibers together. If the patterns do not align, use a

dead man (4 x12-4ft long with tackless strips) to lie across the matched patterns.With the use of a

power stretcher, stretch the short side to make a proper match to the long side. Stay nails may be

needed to hold the pattern in place when stretching. Use approximately ten-foot sections of

stretcher poles to stretch off of the dead man. Continue this procedure down the length of the

seam in both directions. Bowing, and pattern bias must be dealt with during the power stretching

process. A mini stretcher may also be used. A dry line should be used throughout the installation to

check the bow and skew.

• The carpet must be rolled with a 75 to 100 lb. roller in both directions.

• Clean the excess adhesive from the carpet with NuSpraylok™ Overspray Solvent (DK117) using a

white cloth. Stay nails can be removed after the adhesive sets.

• Repeat these procedures until the job is finished.

CLEANING THE NUSPRAYLOK™ SYSTEM

After daily use the wand and hose assembly must be cleaned using NuSpraylok™ One-Shot Hose & Gun

cleaner (DK118). Do not let wand set for more than six hours without cleaning. Follow the cleaning

instructions provided on the DVD.

FLOOR ACCESS

When access to the floor is needed, the following steps should be followed;

• Using a hawk bill carpet knife, carefully get completely under the Duralon backing and pull back

carpet carefully – do not pull on face yarns, as this could cause delamination from the Duralon

backing.

• Before carpet is folded back into place, a light mist of NuSpraylok should be applied to the floor.

This can be done using the 22 oz. can of NuSpraylok.