Installation Instructions

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DURACERAMIC INSTALLATION PROCEDURES

SAFETY

Safety for yourself and others on the job site is your responsibility as

a professional flooring installer. Read and observe the following

safety precautions.

■ Read and follow the safety precautions and warnings printed on

the label of the installation accessory products being used.

Obtain the appropriate MATERIAL SAFETY DATA SHEETS

(MSDS) for information that may be required for products which

may contain hazardous materials. DuraCeramic does not have

MSDS because it is classified as an “article” and not a chemical.

MSDS are available for the adhesive, joint sealer, and grout. You

may obtain an MSDS for these products by calling or writing to

your Congoleum distributor or contacting Congoleum at the

address or phone number listed on this page.

■ Various safety precautions should be taken when preparing subfloors.

■ Wood and concrete: If working on wood or concrete subfloors,

use proper safety precautions when sanding or grinding. Avoid

creating dust. Concrete and cementitious patching compounds

contain crystalline silica, which is a known carcinogen. Wood

dust is classified as a nasal carcinogen in humans. Airborne

wood dust may also be an explosive hazard.

■ Resilient Flooring

WARNING

Do not sand, dry sweep, dry scrape, drill, saw, beadblast, or

mechanically chip or pulverize existing resilient flooring,

backing, lining felt, asphaltic “cutback” adhesive, or other

adhesive. These products may contain asbestos fibers and/or

crystalline silica. Avoid creating dust. Inhalation of such dust

is a cancer and respiratory tract hazard. Smoking by individ-

uals exposed to asbestos fibers greatly increases the risk of

serious bodily harm. Unless positively certain that the

product is a non-asbestos containing material, you must

presume it contains asbestos. Regulations may require that

the material be tested to determine asbestos content and may

govern the removal and disposal of material. Whenever

possible, existing flooring should be left in place and the new

floor installed over the top. If you must remove old flooring

material, contact your retailer or Congoleum Corporation,

Installation Department, P.O. Box 3127, Mercerville,

NJ 08619, for a copy of recommended work practices for the

removal of resilient floor coverings. These practices should be

followed.

NOTICE

Various federal, state, and local government agencies have regu-

lations governing the removal of in-place asbestos containing

material. If you contemplate the removal of a resilient floor

covering structure that contains (or is presumed to contain)

asbestos, you must review and comply with all applicable

regulations. Regulations outside the United States may vary.

Copies of the Resilient Floor Covering Institute (RFCI)

Recommended Work Practices for the Removal of Resilient

Floor Coverings are available from:

Congoleum Corporation Resilient Floor Covering Institute

Installation Department 401 East Jefferson Street

P.O. Box 3127 Suite 102

Mercerville, NJ 08619 Rockville, MD 20850

(609) 584-3888 (301) 340-8580

Please note that the RFCI Recommended Work Practices are

subject to change as new practices are incorporated. It is your

responsibility to determine that the Recommended Work

Practices you use are those in effect.

MOLD AND MILDEW ISSUES

Prior to removing an existing floor following the RFCI

Recommended Work Practices for Removal of Resilient Floor

Coverings (unless state or local law requires other measures), if

there are visible indications of mold or mildew or the presence

of a strong musty odor in the area where resilient flooring is to

be removed or installed, the source of the problem should be

identified and corrected before proceeding with the flooring

work. In virtually all situations, if there is a mold issue, there is

or has been an excessive moisture issue. Visible signs of mold or

mildew (such as discoloration) can indicate the presence of mold

or mildew on the subfloor, on the underlayment, on the back of

the flooring, and sometimes even on the floor surface. If mold or

mildew is discovered during the removal or installation of

resilient flooring, all flooring work should stop until the mold or

mildew problem (and any related moisture problem) has been

addressed.

In areas where flooding has occurred, it is recommended that

damaged flooring be removed following the RFCI

Recommended Work Practices for Removal of Resilient Floor

Coverings (unless state or local law requires other measures).

Any underlayment and subfloor should be allowed to thoroughly

dry and, if necessary, cleaned, disinfected, and otherwise remedi-

ated consistent with the U.S. Environmental Protection Agency

(EPA) guidelines referenced below. Any structural damage or

signs of mold or mildew must be corrected before reinstalling

resilient flooring. This may include for example replacement of

the underlayment and/or subfloor.

For water damage caused by leaking fixtures, the source of the

moisture leak must be located and corrected. Any structural

damage must be repaired and any signs of mold or residual

moisture must be addressed before replacing the resilient

flooring in the affected area.

To deal with mold and mildew issues, you should refer to the

EPA guidelines that address mold and mildew. Depending on the

mold and mildew condition present, those remediation options

range from cleanup measures using gloves and biocide to hiring

a professional mold and mildew remediation contractor to

address the condition. Remediation measures may require struc-

tural repairs such as replacing the underlayment and/or subfloor

contaminated with mold and mildew as a result of prolonged

exposure to moisture.

The EPA mold guidelines are contained in two publications “A

Brief Guide to Mold, Moisture and Your Home” (EPA 402-K-

02-003) and “Mold Remediation in Schools and Commercial

Buildings” (EPA 402-K-01-001). Appendix B of the "Mold

Remediation in Schools and Commercial Buildings" publication

describes potential health effects from exposure to mold, such as

allergic and asthma reactions and irritation to eyes, skin, nose

and throat. These publications can be located on EPA’s website

at www.epa.gov/iaq/molds/

■ Keep work areas free of obstructions, such as tools and scrap or

loose tiles, and dispose of scrap materials promptly and properly

to eliminate a slip or trip hazard.

■ Always use the correct lifting practices.

■ Use only UL

approved electrically powered tools equipped

with a dust collector. Read and follow the safety precautions

and recommended procedures for using power tools.

■ Use heavy-duty extension cords and keep them in good repair.

■ If using minerals spirits as suggested in this guide, CAUTION:

Minerals spirits is a flammable material. Read and follow

cautionary instructions on the labels of these products.

■ Wear non-conducting rubber-soled shoes and use a ground fault

interrupter (GFI) when using power equipment in damp or wet

areas.

■ Wear protective equipment when appropriate such as safety

glasses, respirators, NIOSH-designated dust masks, kneepads,

gloves, etc.

Summary of content (13 pages)

PAGE 1
DURACERAMIC INSTALLATION PROCEDURES SAFETY Safety for yourself and others on the job site is your responsibility as a professional flooring installer. Read and observe the following safety precautions. ■ Read and follow the safety precautions and warnings printed on the label of the installation accessory products being used. Obtain the appropriate MATERIAL SAFETY DATA SHEETS (MSDS) for information that may be required for products which may contain hazardous materials.
PAGE 2
DuraCeramic and DuraCeramic Options DuraCeramic is an innovative flooring product with unique installation procedures that vary from traditional ceramic and natural stone. Its proven success has paved the way for DuraCeramic Options, a floor and wall tile with embossed lines through the center of the tile in both directions.
PAGE 3
INSTALLATION ACCESSORIES INFORMATION DS100 DuraSet Adhesive DS200 DuraCeramic Joint Sealer DuraCeramic Premixed Grout Order Code DS100 DS200 Use specific color code Description Solvent free, acrylic, pressuresensitive adhesive Water-based, flexible acrylic sealer Premixed sanded, acrylic grout Use Installing tile over all approved substrates and wall surfaces For sealing joints in ungrouted DuraCeramic floors only. Not recommended for walls or vertical surface.
PAGE 4
PRODUCT INFORMATION SPECIFICATIONS AND RECOMMENDED USAGE Size (nominal) 15 5/8” x 15 5/8” (40 cm x 40 cm) Gauge (nominal) .160” (4.1 mm) Packaging 10 Pieces/Carton 17 Sq. Ft.; 1.58 m2 Shipping Weight 33 Lbs./Carton NBS Smoke Density Passes Critical Radiant Flux (ASTM E648 >0.
PAGE 5
The surface must be clean, dry and free of dust, dirt, grease or other extraneous material that will inhibit bonding. Thoroughly vacuum floor to remove dust. ■ Deviations in the flatness of the subfloor cannot exceed 1/16” in 1’ or 3/16” in 10’. Check the surface with a straightedge and fill low areas with a portland cementbased latex patching compound. Gypsum-based patching compounds are not recommended.
PAGE 6
grout line space between the tiles. A story pole (board marked with tile dimensions, including grout line width) can also be used in place of a dry layout. • Measure the distance between the last whole tile and the wall. If the distance is less than half a tile, snap a new chalk line one-half the dimension of a full tile away from the original chalk line (Fig. 5). This will provide a balanced layout with larger cut tile at the border.
PAGE 7
• If standard tile spacers are used, it will be necessary to remove one leg of the spacer (Fig. 9) otherwise it will interfere with positioning the tile. Stand spacers on end. Do not place tile spacers flat at the intersection of tiles, they can become bonded, making it difficult to remove them without damaging the edge of the tile. • Position two spacers along the edge of adjacent tiles, then lay the next tile gently against the spacers without forcing it into place (Fig. 10).
PAGE 8
• Warm the tile with a hot air heat gun. Score the surface with a sharp utility knife and break the tile over the score mark by flexing it downward or cut the tile with a coping saw. WARNING: Do not sand painted surfaces. Some paints in the past contained lead. These paints could be the surface coat or an underlying coat on the walls in older dwellings. Painted surfaces that are known to be free of lead can be lightly abraded with a mild abrasive cleaning pad and cleaning solution if necessary.
PAGE 9
■ Continue applying adhesive in small sections and setting tile to complete the wall. ■ Re-roll the entire wall immediately after tiles are set and again just prior to grouting. ■ The wall can be grouted immediately or within 24 hours. Fig. 15 – Lay out additional reference lines for alignment and adhesive application. ADHESIVE APPLICATION WARNING: See warning statement for shock hazards associated with tile installation near electrical outlets and switches.
PAGE 10
Use a spacer 1/2 the gauge ■ Use the measurement of the full pattern repeat to lay out additional chalk lines to keep joints straight (Fig. 21). Fig. 16 - Separated tiles will have one additional grout line. Fig. 21 - Lay out additional chalk lines the exact dimensions of the pattern Diagonal Layouts • Lay out the center and perpendicular lines as previously described for a square layout. Place a mark on each line an equal distance away from the center point (distance from center is arbitrary). Fig.
PAGE 11
Installing Borders and Insets Borders can be created easily by using an accent color or different size tile on a square layout. Plan the layout to allow for a uniform border size using full size tile in the field if possible. When using a square border with a diagonal layout, it is necessary to prepare the cut edge of the diagonal tile where it meets the border.
PAGE 12
• Apply a light mist of water with the spray bottle over the grouted tiles and allow it to remain on the surface for at least 30 seconds. • Use a slightly wet 3M white nylon pad to loosen the grout residue. Apply light pressure while moving the pad in a circular motion (Fig. 27). • Use a firm square edge sponge to remove the excess water solution. Use light pressure and wipe diagonally across the joints (Fig. 28). Do not allow the water to flow into the ungrouted joints or accumulate in finished areas.
PAGE 13
contact with the floor. Glides should be equipped with self-adhesive felt pads to avoid scratching the surface of the floor. The pads should be checked periodically for grit and wear and replaced when necessary. ■ Heavy furniture or appliances that are not moved often should be equipped with flat, nonstaining composition furniture casters or cups of appropriate size - available square from 1 1/2” to 2 5/8” and round from 1 3/8” to 1 5/8”. Fig. 29 - Cut along the center of the grout line after heating it.