thread507-324259
Last year I posted a question about wood laminate flooring on a slab-on-grade (but not basement) that buckled in 2 locations in the 9 m (east-west) by 27 m (north-south) room, a few months after it was installed in February of last year. The buckling occurred at about June 20, 2012. In July of 2012, a perimeter expansion joint was cut all around the room although my observations at the time were that this was not done at the steel door frames.
The room is generally 24 m log, but there is a 3 m wide portion that is 27 m long and it is in this longer portion where the buckling occurred.
I am told that there was plywood underlay placed under the flooring, then a 2 mil poly sheet, then a cushioning material and then the laminate flooring. I am told that the plywood underlay also buckled, although I did not see that myself.
In winter the room is at low humidity, reportedly measured to be about 25%; and in summer when the air conditioning is running it is about 70%. Mechanical engineers that we have discussed this with say that is the expected range unless special dehumification is built into the A/C system (which they say is done only in special buildings these days because of the increased energy use with such systems).
Well, June of this year (2013) it buckled again about June 20th and near the same 2 locations as last year. These locations are approximately in line with the doors at the north and south ends of the room (27 m long) although not precisely in line with the vertical metal door frame jambs. The long dimension of the flooring boards is parallel to the long dimension of the room.
The manufacturer's printed instructions say to install expansion joints at 8 m centres transverse to the board length and 10 m centres parallel to the board length. This has not been done. We are told by the installation contractor, and by the flooring supplier, that the expansion joint cover would protrude about 10 mm above the floor. Since this is a mulitpurpose room in a place of worship, used for assembly and speakers, as well as a gym, and for dance, and there are both the young and the elderly around, the concern is that such expansion cover protrusions will be a tripping and public safety hazard.
I am being asked to investigate and report whether we should once more try to make the flooring work, or throw it away (the exisitng flooring is worth about $18,000).
QUESTIONS;
1. Does anyone know if there is an expansion joint cover that has been used with this type flooring (9 mm thick laminate) that does not project more than say a couple of millimetres above the floor, that might perhaps safely be used and would not be a hazard when the room is used as a gym or for dance, etc., although even a 2 mm projection might be a hazard I suppose?
2. I suppose that if the plywood buckled, then that would also have to be addressed. Is plywood normally butted tight panel to panel?
3. The cost of replacing the 27 m long by 3 m wide swath of the floor (they would have to do this particular replacement because they sawcut the boards in July at the buckled locations so that they could get rid of the buckle and continue to use the room) is about $3,000. The question is whether it is worth having one more try at making this flooring work (by ensuring it is free of the door frames; cutting a gap in any underlying plywood) or would we just be throwing good money after bad? There are other issues with the floor, such as that it shrinks in winter and the joints between board ends open up; it is not supposed to be washed with water, so is hard to keep clean; it is not bonded, so when someone drops their cane it sounds like a drum reverberating in the room; etc.).
Last year I posted a question about wood laminate flooring on a slab-on-grade (but not basement) that buckled in 2 locations in the 9 m (east-west) by 27 m (north-south) room, a few months after it was installed in February of last year. The buckling occurred at about June 20, 2012. In July of 2012, a perimeter expansion joint was cut all around the room although my observations at the time were that this was not done at the steel door frames.
The room is generally 24 m log, but there is a 3 m wide portion that is 27 m long and it is in this longer portion where the buckling occurred.
I am told that there was plywood underlay placed under the flooring, then a 2 mil poly sheet, then a cushioning material and then the laminate flooring. I am told that the plywood underlay also buckled, although I did not see that myself.
In winter the room is at low humidity, reportedly measured to be about 25%; and in summer when the air conditioning is running it is about 70%. Mechanical engineers that we have discussed this with say that is the expected range unless special dehumification is built into the A/C system (which they say is done only in special buildings these days because of the increased energy use with such systems).
Well, June of this year (2013) it buckled again about June 20th and near the same 2 locations as last year. These locations are approximately in line with the doors at the north and south ends of the room (27 m long) although not precisely in line with the vertical metal door frame jambs. The long dimension of the flooring boards is parallel to the long dimension of the room.
The manufacturer's printed instructions say to install expansion joints at 8 m centres transverse to the board length and 10 m centres parallel to the board length. This has not been done. We are told by the installation contractor, and by the flooring supplier, that the expansion joint cover would protrude about 10 mm above the floor. Since this is a mulitpurpose room in a place of worship, used for assembly and speakers, as well as a gym, and for dance, and there are both the young and the elderly around, the concern is that such expansion cover protrusions will be a tripping and public safety hazard.
I am being asked to investigate and report whether we should once more try to make the flooring work, or throw it away (the exisitng flooring is worth about $18,000).
QUESTIONS;
1. Does anyone know if there is an expansion joint cover that has been used with this type flooring (9 mm thick laminate) that does not project more than say a couple of millimetres above the floor, that might perhaps safely be used and would not be a hazard when the room is used as a gym or for dance, etc., although even a 2 mm projection might be a hazard I suppose?
2. I suppose that if the plywood buckled, then that would also have to be addressed. Is plywood normally butted tight panel to panel?
3. The cost of replacing the 27 m long by 3 m wide swath of the floor (they would have to do this particular replacement because they sawcut the boards in July at the buckled locations so that they could get rid of the buckle and continue to use the room) is about $3,000. The question is whether it is worth having one more try at making this flooring work (by ensuring it is free of the door frames; cutting a gap in any underlying plywood) or would we just be throwing good money after bad? There are other issues with the floor, such as that it shrinks in winter and the joints between board ends open up; it is not supposed to be washed with water, so is hard to keep clean; it is not bonded, so when someone drops their cane it sounds like a drum reverberating in the room; etc.).
