PVC plastic flooring

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1. The English name is PVC (poly-vinyl chloride); the Chinese name is plastic flooring. Some common terms used to refer to it include PVC/LVT/LVP/WPC/SPC/Vinylfloor/vinyl plank. Its main component is polyvinyl chloride; PVC flooring originated in Europe and the United States, and it is very popular in those regions as well as in the Asia-Pacific area. In China, 2.0MM commercial flooring is currently the most common type, while SPC and WPC flooring is also gradually gaining popularity. 5 common ways of referring to plastic flooring: 1.1 PVC: polyvinyl chloride; 1.2 LVT: luxury vinyl tile; 1.3 LVP: luxury vinyl plank; 1.4 Vinyl floor; 1.5 Vinyl plank; 1.6 WPC: wood plastic composite (in fact, due to the difficulty in processing and recycling the material when wood flour is added, there is no wood flour in the formulations of WPC flooring at present); 1.7 SPC: stone plastic composite. In Europe and America, this type of flooring is called RVP (rigid vinyl plank), that is, rigid plastic flooring. 2. Classification of plastic flooring: Currently, PVC sheet flooring can be made in two types. One type is a homogeneous flooring with the same pattern and material from the bottom to the top; if its surface gets damaged or scratched, it can be repaired by grinding and waxing it. Another type is a composite structure in which the top layer is a pure PVC transparent layer, with a printed layer and a foam layer added underneath; it is clear that materials with solid transparency of the same quality are far superior to composite types. In terms of form, they are divided into rolled flooring and sheet flooring ； The products highlighted in this article are LVT and WPC floors, which belong to the category of semi-rigid sheet plastic floors, while SPC (RVP) floors fall under the category of rigid sheet floors. Currently, there are mainly three types of LVT floors: vinyl locking, dry back, and loose lay. From another perspective, PVC floors can be classified by installation method into ordinary (Dry Back), click-type, and glue-free (Loose lay) types. At the same time, WPC wood-plastic flooring and SPC stone-plastic flooring are also in a phase of active promotion and rapid development in both domestic and international markets. 2.1 Comparison between dry back and loose lay in plastic flooring 2.1.1 Similarities: Both are types of PVC flooring, they have the same specifications and dimensions; some of the dimensions are identical ； The Dry back product is available in eight specifications: 942*157, 1227*157, 1227*187, 1227*235, 914.4*101.6, 470*470, and 608*308 (units: millimeters) ； For loose lay, the main dimensions are 942*157, 1227*157, 1227*187, 1227*235, 470*470, and 608*308 (units: millimeters). For Click, the available sizes are 936*150, 1220*150, 1220*180, 1220*228, 1500*228, and 600*300 (units: millimeters); be sure to compare these with those of dry back. WPC currently comes in two sizes: 1217*146, 1217*178, and 596*296 (units: millimeters). SPC mainly has the following sizes: 1210*150, 1210*181, 203*1219, 178*1219, and 152*1219 (units: millimeters). 2.1.2 Differences: A. Installation method: Dry back requires the use of adhesives such as bonding glue; it’s also known as “glue down.” Loose lay can be installed directly (the underlying layer of loose lay has a black coating on it, making it impossible to move it on a flat surface.). B. Thickness: For dry back, our factory only produces products with a thickness of 2.0 mm or more; we do not produce products with lower thicknesses. Loose lay generally has a thickness of 4.0 mm or 5.0 mm, consistent with that of Click. C. Wear resistance: Generally, dry back products with a thickness of 2.0 mm or 2.5 mm have a wear resistance of 0.1 mm–0.5 mm, while those with a thickness of 3.0 mm have a wear resistance of 0.1 mm–1.0 mm. In theory, dry back products with a thickness of 2.0 mm or 2.5 mm could have a wear resistance of over 0.5 mm, but this is not cost-effective. Additionally, the formulas for the base material and intermediate layers would need to be changed and tested; currently, our factory does not produce such products ； For loose lay, at present, 4.0mm and 5mm wear-resistant layers are basically used only for 0.3mm and 0.5mm wear resistance, for the same reasons as above. D. Price: Dry back is cheaper, while loose lay is more expensive. E. Curing time: Dry back requires 24 hours for curing after tempering, whereas loose lay, like the snap-fit series, needs 48 hours. F: The flexibility of the two differs; loose lay products are significantly softer than dry back products. Such characteristics can also be used as distinguishing features. At the same time, what is most noticeable is a layer of black skin at the bottom of the loose lay; this can be scraped with a fingernail to determine whether it is soft or hard. 3. Composition of plastic flooring: Components of PVC flooring include PVC resin powder, stone powder, plasticizers, stabilizers, and carbon black; the main components are polyvinyl chloride and stone powder. Plastic flooring is composed, from bottom to top, of a backing layer, a core layer, glass fibre, decorative paper, and a wear layer. 4. PVC Certification: Currently, the certifications for PVC products include Floor Score, DIBT, CE, ISO14001:2004, ISO9001:2008, and German TÜV Rheinland. 5. The most important product specifications for PVC • Stability: Rate of shrinkage and expansion at 80°C for 6 hours – 0.25%, 0.15% (industry standard). • Warping under heat: At 80°C for 6 hours, according to EN13 standards, it should be 15 kgs/5cm; if V-clips are used on the shorter sides, this value should be 4.2 mm > 15–18 kgs/5cm. • Peeling strength: The strength of adhesion between the colored film and the underlying material; this is also a useful indicator for determining the quality of recycled materials. • Scratch resistance and wear resistance • Brightness: 10 +/–2.6. Calculation of the area required for flooring: If the area to be covered is 50 square meters, a portion of the area needs to be cut off at the walls, and with a typical waste rate of 5%, the actual area required is 50 * (1 + 5%) = 52.5 square meters. Standards and procedures for PVC floor installation; PVC flooring requires high standards regarding the base surface on which it is laid. Before construction, the existing floor surface must be inspected in strict accordance with the \"Floor Foundation Inspection Standards\". For floor foundations that do not meet the requirements, suggestions should be submitted to the client; 2mm of self-leveling cement should be applied, and the surface must be sanded before construction can proceed. Here are the detailed key points: 1. Key points regarding the subbase: Regardless of the type of material used as the subbase for PVC flooring, if the leveling layer is damaged or its levelness exceeds a deviation of 5 mm, the subbase construction contractor shall bear the responsibility for ensuring quality. II. Requirements for the substrate when laying PVC flooring: The condition of the substrate not only has a significant impact on the appearance of the installation, but also relates to the lifespan and durability of the flooring. Therefore, the base layer should be kept dry, solid, rigid, smooth, flat, clean, and free of dust and grease. 1. Concrete substrate: The newly poured or cast-in-place concrete substrate must meet the standards for installing PVC flooring, and its design shall comply with the design strength requirements for both static and dynamic loads of the building. The concrete base must be solid and completely dry, with a smooth, dense, and even surface free from any imperfections such as bumps, cracks, or marks. 　　If there is a moist subbase beneath the concrete base, a moisture barrier must be installed in the floor to prevent moisture from seeping in. Moisture-resistant additives and curing agents cannot replace the moisture barrier. Each 25 mm thick layer of freshly poured concrete base should have a drying period of at least one month. Try to conduct tide gauge tests before installation. 　　The substructure on which PVC flooring is laid must be free of curing agents, oils, greases, paint, dust, and any other substances that could prevent the adhesive from bonding properly; it must also be free of cracks, honeycombing, or bulges. If the surface does not meet the requirements, it should be repaired with a cement mortar leveling layer or by using self-leveling cement. 　　If the concrete surface has already been treated with a curing agent, hardener, sealant, or release agent, these substances must be completely removed through grinding, sandblasting, or polishing before the floor is laid, as they will weaken the adhesion of the adhesive. 　　2. Wooden subfloor: All wooden subfloors must have at least 450 millimeters of air circulation space reserved during installation to prevent the floor from warping and the subfloor from undergoing excessive deformation. The newly installed wooden substructure should be solid and made of air-dried wood, without excessive compression or warping. 　　All loose planks in the existing wooden substructure should be re-secured, and those that are severely worn or damaged must be replaced. If necessary, the floor can be sanded to make its surface smooth and free of imperfections. The subbase may be covered with a composite plywood or an approved fiber-cement elastic flooring layer. The leveling material must be placed 75 millimeters around the edge of the slab, with a margin of 10 millimeters, and fixed throughout the slab at a depth of 100 to 150 millimeters. 　　3. Existing PVC floor and rubber floor substrate: It is recommended to remove the current PVC floor and rubber floor. If this cannot be achieved, take appropriate and sufficient measures to ensure that the old flooring meets the standards required for installing new flooring. 　　Existing PVC floors and rubber floors must be smooth (without deformation or bulges that could affect their appearance after installation), intact, firmly bonded, and properly installed on the recommended subfloor. The surfaces of existing PVC and rubber flooring must be free of any attachments, as well as signs of moisture, alkalis, salts, or hydrostatic pressure. Wax and other coatings on the existing material must be completely removed, and dents and damaged areas should be replaced or repaired. Installation on existing PVC and rubber flooring will reduce the surface compressive strength. 　　Note: Existing PVC flooring and rubber flooring may contain asbestos that is difficult to detect, and regulations may require testing the materials for asbestos content. The installer shall ensure that the methods of operation are safe, do not pose a risk to health, and comply with all legal requirements. 　　When installing on existing PVC or rubber flooring, the flooring adhesive may require more curing time to prevent bubbling of the flooring. 　　4. Expansion joints: It is recommended not to cover expansion joints with PVC flooring. PVC floor expansion joint covers should be installed at the expansion joints. Working conditions for laying PVC flooring: During the pre-installation, installation, and post-installation phases, the temperature in the area where the flooring will be installed should be maintained at at least 18°C for 48 hours. Please note that the low temperature of the substrate has a significant impact on the pot life of the adhesive. 4 Requirements for preparing the subbase for PVC flooring Basic requirements: The subbase for PVC flooring should be flat, dry, solid, and free from dust and dirt. The construction steps can be summarized in five words: first, \"leveling\"; second, \"grinding\"; third, \"drying\"; fourth, \"sweeping\"; fifth, \"vacuuming\". 　　“\"Leveling\" refers to removing any protrusions such as existing paint or hardened cement on the surface, filling in depressions, so as to achieve a flat surface. 　　““Grinding” refers to using a grinder to level the uneven surface so that the difference in surface thickness over any two consecutive square meters is no more than 2.0 millimeters. 　　“\"Drying\" refers to allowing the leveled surface to dry naturally in the air or using heat to speed up its drying process, so that the moisture content of the entire surface does not exceed 6%. 　　““Sweeping” refers to using a broom or dust mop to clean the floor and all corners. 　　“\"Sucking\" refers to using a large vacuum cleaner to thoroughly clean the surface where work is being done as well as the surfaces of the cut materials, several times over, in order to remove all tiny particles from the surface; at this time, it is necessary to wear clean shoes while performing this task. 5. Preparation for installing PVC flooring 1. Before installing the flooring, it should be laid out in the construction site at an ambient temperature of above 18°C for at least 24 hours, in order to eliminate any stresses present in the material. 　　2. First, prepare the construction tools: check the operation and power usage of the main mechanical equipment, and arrange for the necessary power and water supplies for construction. Imported tools should not be used on the same power strip as other power tools, and must be equipped with a voltage stabilizer and power protection devices. Avoid excessive current from causing the machine to fail to operate properly, thereby delaying the schedule. Check the usage of various types of manual tools, such as floor material cutting knives, grooving tools, joint cutters, and adhesive scraping boards. Also, ensure that the surface of the adhesive application rollers is clean and smooth; if it does not meet the required standards, replace the worn-out parts promptly to maintain construction quality. 　　3. Apply the interface agent; after the self-leveling compound has been applied, there may still be tiny particles and dust on the surface. In such cases, it is necessary to use a grinder for further smoothing. Some dust remains on the ground after grinding, and it is essential to apply the water-based interface agent once again. This is done to seal the small pores and dust on the surface of the self-leveling compound, thereby making the surface smoother and improving the adhesion of the adhesive, and preventing the floor from bulging or peeling off after construction is completed. 　　4. Check the construction environment: Before laying the floor, the temperature at the construction site should be checked; the indoor temperature should be at least 18°C, and the relative air humidity should not exceed 75%. The work area should be kept well-ventilated, and contaminants should not be allowed to enter other parts of the building. 　　5. Placement of materials: Before construction, the PVC sheet flooring must first be unrolled and laid flat on a level surface; once it has regained its flatness and the stress in the material has dissipated, it can then be placed in the room where the adhesive will be applied. Arrange the cutting area properly to ensure it is free of dust and sand particles. Special transportation tools should be used for transporting and handling rolled materials; any damaged flooring that occurs during this process must be cut away using a plastic trimmer before the material is processed further. 6. Measurement and Cutting of PVC Floor Tiles Basic requirements: Determine the dimensional errors by combining on-site measurements with the layout plan; identify the key points according to the layout plan, and use a pencil line guide to outline the area where the floor tiles will be laid. Cut the material along the contour lines, arrange the weld lines and patterns properly to minimize material waste. 　　Key operating points: The cutting of materials must be handled by a dedicated person; if the floor has directional patterns, it is essential to always pay attention to the consistency of that direction; accurate data must be obtained on-site for each cut; and when cutting, it is necessary to leave a margin of 2-3 centimeters between each piece of material. 7. PVC Floor Laying and Joint Treatment Basic methods and requirements: Use adhesive to attach the PVC floors firmly and evenly to the subfloor. The overlapping parts of the floors should be joined with a slight gap between them, with that gap ranging from 0.2 to 0.5 mm. 　　Construction tips: Use a glue spreading strip to apply the glue evenly on the floor, in accordance with the relevant application guidelines and specified amounts. 　　Types and application ranges of adhesives: 1. Dispersed-type floor adhesives are single-component adhesives suitable for bonding various types of PVC floor tiles and sheets, PVC-backed carpets, vinyl asbestos boards, CV-type sheets, as well as non-absorbent floor substrates. Curing time: about 10-20 minutes; time available for flooring: about 30-40 minutes. 　　2. Super strong floor adhesive is a high-grade, powerful dispersive adhesive used for bonding PVC floor materials, rubber sheets and blocks with a thickness of 2.5 millimeters, as well as PVC composite floors, to floors, walls, and stairs. Super strong floor adhesive is suitable for various absorbent and non-absorbent floor substrates. Curing time: Wet bonding method: Absorbent substrate, 10-20 minutes. Pressure-sensitive dry adhesive method: non-absorbent floor substrate, 30-60 minutes. Time for laying flooring: Wet adhesive method: absorbent subfloor, 60 minutes. Pressure-sensitive dry adhesive method: non-absorbent floor substrate, approximately 120 minutes. 　　3. The antistatic floor adhesive is a high-strength dispersible adhesive with a conductive formula, used for bonding various conductive or static-dissipative PVC floor rolls and slabs to walls/floors and stairs, as well as rubber rolls with a thickness of up to 3.5 millimeters and rubber slabs with a thickness of up to 2.5 millimeters. Curing time: Wet bonding method: Absorbent substrate, 10-20 minutes. Pressure-sensitive dry adhesive method: non-absorbent floor substrate, 30-60 minutes. Time for laying flooring: Wet adhesive method: absorbent subfloor, 60 minutes. Pressure-sensitive dry adhesive method: non-absorbent floor substrate, approximately 120 minutes. 　　4. Linen floor adhesive is a high-strength dispersible adhesive with rapid and strong initial adhesion as well as cohesion, making it particularly suitable for bonding linen floors and parquet floors. As well as suitable for inorganic absorbent floor substrates. Curing time: 0-5 minutes. Time required for flooring installation: approximately 15–20 minutes. 5. The polyurethane flooring adhesive is a solvent-free, reactive two-component polyurethane adhesive that is suitable for bonding various materials such as PVC, rubber, linoleum, tiles, stone, expanded polystyrene, wood planks, gypsum board, cement board, and artificial grass. As well as suitable for various absorbent and non-absorbent subbases. Curing time: Not required. Floor-laying time: approximately 40-50 minutes. 　　6. The polyurethane antistatic floor adhesive is a solvent-free, reactive two-component polyurethane antistatic floor adhesive that can be used for installing antistatic PVC and rubber floors on heavy-duty substrates such as absorbent and non-absorbent commercial and industrial floors. Curing time: Not required. Floor-laying time: approximately 40-50 minutes. 　　Method of laying PVC flooring: First, lay the rolled flooring flat on the ground; for lengths exceeding 8 meters, the flooring should be laid in two sections, one at the front and one at the back. Then roll up one side of the floor, apply glue evenly on that rolled-up area, and wait until the solvents in the glue have evaporated and it has gained viscosity before proceeding with bonding. When bonding, push the floor with your hand in the same direction to prevent air from remaining between the floor and the glue. The time it takes for the glue to evaporate varies depending on the temperature at which it is applied. For example, at a normal temperature of 20 degrees Celsius, it takes 30 minutes for the glue to evaporate; at this point, the glue changes from milky white to translucent. When touching the surface covered with glue, no strong stickiness is felt, and this is when it is suitable to apply the adhesive. Applying it at the right time ensures that there are no bubbles or bulges in the floor. Use the same method to attach the other half as well, and press the floor firmly against the ground from all directions using a roller; this will help the glue bond more tightly to the floor. Roll over both sides sequentially with the roller. If there are bubbles, they should be pushed out using cork or by hand; 24 hours after the floor has been cleaned, the welds should be sealed off using a welding gun. 　　Applying a cross-sectioning agent to the surface of self-leveling cement is an effective method to control floor bulging. The main reason for floor bulging is that the surface of the substructure is not clean; dust and other residues affect the bonding effect. The most effective method is to apply an interface agent evenly on the surface of the substructure, which can effectively prevent the floor from bulging. Eight-slot welding: Basic requirements: The welds should be straight and smooth, without cracks, burn marks, or breaks, and they should blend in terms of color with the entire floor. 　　Key operating points: Use a grooving tool to create a U-shaped groove 2.5 millimeters wide between the two floor panels, with a depth equal to three-quarters of the floor panel’s thickness; the weld line should be straight. Use a welding gun to remove any glue or dust from within the groove. Set the welding machine to the appropriate temperature, and once the hot air is stable, insert the weld wire into the welding tip and carry out welding at a constant force and steady pace. Half an hour after welding, use a butterfly blade in combination with a shovel to remove the excess weld wire above the surface, doing this in two steps – first a rough removal and then a more precise one. The specific welding methods for various PVC floors are as follows: 1. Heat fusion welding: For heat fusion welding, professional floor welding tools should be used; such machines are designed specifically for welding PVC, rubber, and linoleum floors. Different floor materials require different welding temperatures; materials such as PVC or rubber floors have upper temperature limits for heat fusion welding. Proper and standardized procedures ensure perfect welding of the floors, achieving the most optimal installation result. 　　(1) Standards for welding speed and temperature: The traveling speed of the welder used for PVC flooring should be between 3.5 meters and 5.0 meters per minute, while the temperature should be maintained between 500 degrees and 600 degrees. The traveling speed of the welder used for welding rubber floors and linen floors should be between 3.0 and 3.4 meters per minute, with the temperature to be maintained between 400 and 450 degrees. If tiny beads of tin appear at the junction between the floor surface and the welding rod, it indicates that the welding rod and the floor have been welded together. 　　(2) Preparation for grooving: A groove that can accommodate the welding rod must be created in the floor weld before welding; the depth of this groove should be less than 2/3 of the floor’s thickness. If a 4 mm electrode is used, the groove depth should be less than 1.8 mm. If the depth created by a semi-circular grooving tool exceeds 1.8 millimeters, it will affect the quality of the double-sided welding, and two black bands may form at the junction between the floor surface and the weld rod. In such cases, reduce the grooving depth to 1.3 millimeters. 　　(3) Preheating of the welding gun: Before welding, heat the thermal fusion welding gun and set it to its maximum power level. Before operation, direct the hot air flow to the sides, so that it does not pass through the nozzle and reach the floor. This prevents the floor from burning due to excessive heating. 　　(4) Welding of the floor: Remove the glue and dust from within the grooves that have been created. Set the welding machine to the appropriate temperature, and once the hot air is stable, insert the welding wire into the quick-welding nozzle and carry out welding at a constant force and uniform speed. Half an hour after welding is complete, use the sliding plate of the welding groove along with a crescent-shaped shovel to remove any excess welding wire above the surface, in two separate steps. 　　(5) Trimming the electrode: 10–15 minutes after welding is completed, use a crescent-shaped scraper to trim the protruding electrode in two steps. First, place the crescent-shaped scraper on the trimming guide plate and remove the excess electrode material; after this step, there will still be an excess of 0.5 millimeters of electrode material protruding above the floor surface. Then, use the scraper to trim away the remaining portion, so that the seam ends up being perfectly smooth. 　　2. Polyvinyl chloride – cold welding technique: Used for welding the seams of floors, wallpapers, etc., whose surface structure has polyvinyl chloride properties. 　　(1) Cold welding nozzle A + cold welding fluid (matte type): Suitable for welding PVC flooring, wallpaper, and fibers with polyvinyl chloride properties in their surface structure, as well as creating neat, narrow seams in resin boards. Using the metal needle on nozzle A can weld the seams cleanly and nicely. During installation, masking tape is applied to the joints; the tape is then cut along those joints. After distributing the cold welding fluid evenly in the floor joints for about 20 minutes, the masking tape can be removed. People can walk on it after ten minutes, and the welding fluid will be completely solidified in about an hour, making the seams barely noticeable. Advantages: Waterproof, dirt-resistant, with no shrinkage or bulging at the seams. The matte finish of the cold welding fluid can be precisely adjusted to meet the requirements of various PVC floors. 　　(2) Cold welding nozzle C + cold welding paste (matte type): Suitable for welding wider seams in PVC flooring and wallpaper, as well as for repairing seams up to 4 mm wide. It is also suitable for welding the joints between PVC corner trim and walls as well as floors. In humid environments such as hospitals and laboratories, using cold solder paste to weld the joints between wall corners and the floor yields the best results; this method prevents water leakage after welding. It should be noted that cold solder paste requires a room temperature of over 18°C when in use. If a cold solder paste is required, it can also be supplied in a specific color. 9 Cleaning, Waxing, and Daily Maintenance Basic requirements: Remove any adhesives, dust, shoe prints, etc. that may have accumulated during installation. To extend the floor’s lifespan and facilitate future maintenance, it is necessary to apply a base wax and a top wax to the floor. 　　Operating procedures: Thoroughly clean and vacuum the area; mop the entire floor with a neutral cleaner or clean it using a machine at low speed. Do not wash the floor with large amounts of water for at least four to five days after the work is completed, to prevent water from seeping in and affecting the joints and the adhesion of the glue. Use a 3M red cleaning pad to scrub the floor, then use a large absorbent machine to remove any remaining residues, ensuring the floor is completely clean and dry. Use a waxing machine with a rotation speed of (175 to 1500 revolutions) to apply 3M Super Hard Shine Wax evenly on the floor, and then use a high-speed polisher to polish the wax on the floor until the desired shine is achieved.