Product knowledge 101 ramsey

Mohawk University Tom Ramsey

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Welcome Arbor

Contract Carpets

Welcome Arbor Contract Carpets

Product Knowledge 101

Tom Ramsey

WoolNylonAcrylicsOlefin ( Polypropylene ) Polyester

Carpet Fibers

Customers buy a carpet’s “face” – the fibers. Fiber is their major decision-variable. It serves both their FASHION wants – what they see – and their FUNCTION needs – what holds up under the brunt of foot traffic. Here’s what you’ll want to learn about the different characteristic of common carpet fibers.

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Mohawk Yarn Characteristics Grid

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Natural fiber shorn from sheep. The type is determined by breed of the sheep and the climate. Most fabrics use long and short wool fiber interlocked together

Wool has some remarkable natural abilities : • To hold or release water vapor as the climate requires. It serves as a

natural humidifier. • To be easily cleaned. Wool fibers, seen through a microscope, show

overlapping scales arranged much like roof shingles. The scales keep dust and dirt near the surface of the carpet pile, where a vacuum can readily suck them out.

• To hide soil. The scales scatter light shining on it. When the scales scatter the light-rays, the eye cannot see the soil as well. The soil is less visible.

• To resist burning. Wool is naturally flame resistant. Rather than burning, it forms a char that will neither melt nor drip.

WoolLess than 1% of market

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Characteristics: Natural resilience, good resistance to abrasion, good texture retention, good resistance to soil, and good clean-ability.

Advantages: Limitations:Prestigious ExpensiveExcellent cover and bulk High staticResilient Poor stain removalVersatile AllergenicFlame resistant Inconsistent quality

Wool

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The first synthetic fiber, made into carpet in the 1940’s. It is synonymous with strength and abrasion resistance.Characteristics:Good resilience, outstanding resistance to abrasion, good texture retention and good clean-ability.Nylon 6 Vs Nylon 6,6The basic difference between these two nylons is their molecular structures. • Type 6,6 nylon is extruded from Hexamethylene Diamine and Adipic acid. The

polymer contains two strands of 6 carbon atoms (hence, “6/6”). • By contrast, Type 6 is extruded from caprolactam. It yields one polymer with

6 carbon atoms.Some minor differences exist between the two types of nylon. However, the differences between samples equally made and tested produce no consequences to consumers.

Nylonapproximately 65 % of market

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Advantages; Limitations:Good bulk and cover Costs more than polypropyleneClear colorsLong wearingResilient Dye versatility

Nylon

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Produced about 1960. A solution dyed version of the fiber is used in indoor-outdoor carpets.

Characteristics:Good resistance to abrasion, very good resistance to soil and very good clean-ability. Adequate resilience and texture retention.

Olefin ( Polypropylene )approximately 23 % of market

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Advantages: Limitations:Inexpensive ResiliencyAbrasion resistant Color rangeMoisture resistant Flammability rating

(lower than Nylon)Fade resistant Low melting point

(friction burns)Stain resistantLow static

Olefin (Polypropylene)

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Produced after 1965. And became popular because of its soft, luxurious appearance, close to that of wool and for its bright lustrous shades.

Characteristics:Good resistance to abrasion, very good resilience if twisted right, good texture retention and adequate clean-ability. Naturally stain resistance.

Advantages: Limitations:Highest melting point Less durable than

Nylon

Polyesterapproximately 11% of market

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Introduced about 10 years after nylon. Often blended with modacrylic fibers as a guard against potential flammability. However, improvements in composition have reduced flammability to no more than wool.

Characteristics:Warm, luxurious appearance like wool, good resilience, resistance to abrasion, texture retention and good clean-ability.

AcrylicsLess than 1% of market

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SmartStrand® Made with DuPont™ Sorona®

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It is not simply another polyester…

• There are many fibers that fall within the polyester family, as defined by the FTC.

• Not all fibers within a family have the same characteristics, they simply have something in common chemically.

• Think of Nylon and Kevlar – same family, very different characteristics.

Sorona® fiber has unique chemistry, molecular design and fiber structure

Sorona®’s wear performance continues to be like nylon

FTC has agreed unanimously (5 to 0) that the petition for a sub-class generic has merit

Temporary FTC Classification as “PTT 001”

Only 5 approved sub-class generics in last 50 years

FTC Petition Merited

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SmartStrand™ made with DuPont Sorona polymer

• Poly-trimethylene Terephthalate - PTT (3GT)

• Poly-ethylene Terephthalate - PET (2GT)

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Excellent Durability

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Why is it so Durable?

It’s in the DNA of the fiber!

2GT 3GT

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What Makes This Product Special…

• Engineered-In stain protection• Will never wash off or wear off• Durability as good as if not better than nylon• Inherently soft hand• Strong consumer brand names

• Karastan• Mohawk• DuPont

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Engineered-In Stain Protection

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• Innovative technology that will allow 37% of the polymer to be created from corn sugar and not petroleum

• Uses 30% less energy (petroleum) than making nylon 6.

• Emits 63% less “Green House Gases” – CO2

• No chemical treatment needed to resist stains

• Recommend cleaning with clean hot water extraction

SmartStrand (Triexta)

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PTT is also naturally soil resistant. Therefore, wear and

maintenance will not diminish stain resistance, or soil resistance.

Carpet with Triexta (PTT) fiber has the best warranties in the

industry.

Limited Lifetime Stain

Including mustard, coffee, herbal teas, household bleach, acne

medications and other water-soluble, non-wax/oil based stains… includes

pet urine


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Innovative Technology that will allow 37% of the polymer to be created from corn sugar and not petroleum

Uses 30% less energy (petroleum) than making nylon 6

Emits 63% less “Green House Gases” – Carbon dioxide

No chemical treatment needed to resist stains

Recommend cleaning with clean hot water extraction


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Remember: Why Engineered-In Stain Protection Is Better Chemical applied to carpet is temporary regardless of how it is applied (Stain

resistance and soil resistance)

Engineered-In is permanent

Mill applied chemistries diminish over time with required steam cleanings

SmartStrand’s Engineered-In protection doesn’t rely on chemicals and never goes away


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This is a revolutionary new carpet fiber, different from anything on the market. The official name is SmartStrand fiber made with DuPont Sorona polymer.

SmartStrand fiber made with DuPont Sorona polymer is a Mohawk exclusive. No other carpet manufacturers have this polymer.

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Four Reasons:1. The engineered-in stain and soil protection of both

SmartStrand fibers remains with the fiber for life. No chemicals are applied to the carpet to prevent stains or make water bead up. Unlike topical treatments, the staining and soiling protection of SmartStrand will not diminish with wear or with carpet cleanings.

2. SmartStrand polymers are inherently more resilient than P.E.T. polymer and have floor performance comparable to that nylon carpets.

3. SmartStrand polymers produce inherently soft fibers without lowering the denier.

4. Mohawk’s DuPont Sorona products carry a Limited Lifetime stain warranty.

Why is SmartStrand superior?

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Smart Product…

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®

Any Questions About ?

What is fiber?

What is yarn?

Understanding Fiber / Yarn

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From Pellets to Carpet

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Staple Vs. Filament

After the fiber is crimped, continuous filament fiber is wound onto a spool to ready it for shipping. A staple yarn is cut into 6 to 8 inch lengths and bound into 600 lb. bales ready for shipping.

Which fibers are staple & which are filament?All Olefin fibers are filament. Polyester can be staple or filament. (Mostly staple) Acrylic is made into a staple fiber. Nylon can be staple or filament and is used extensively in both applications. All natural fibers are staple i.e., wool, cotton, etc.

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Why do we make staple?

This question is one of the most misunderstood in the carpet industry. Staple is not scrap yarn. Staple does not fuzz forever. Staple does not accept a dye better.

The main reason for staple fiber is for dying uniformity and a finished look that can only come from spun yarn.

How many sheep does it take to make a rug? What are the odds that each sheep’s fiber will be uniform with each other? Early continuous filament fiber did not dye uniformly and tended to streak. It was very difficult to make a continuous filament carpet in a cut pile, solid color Saxony. Cutting the filament fiber into 6 to 8 inches and then blending the fiber eliminated the dyeing differences.

The staple process lessens the cost in manufacturing, although the fiber must be re-made or spun into yarn again.

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Staple fiber, when constructed the same, performs as well as continuous filament fiber under the same conditions.

The main difference is that staple will fuzz for 3 to 6 months. The duration of the fuzzing is dependent on the quality of the customer’s vacuum and maintenance, the level of traffic, twist of the fibers, pile height and the dying method.

When customers are considering a carpet of staple yarn, explain to them that there will be a shedding of loose fiber. Give them realistic expectations. "Mam, this carpet is made of staple yarn. It will fuzz for 3 to 6 months just like any fine wool carpet. Do not be concerned if your vacuum bag fills with loose fiber. The more you vacuum the carpet with a good vacuum, the sooner the fuzzing will stop. “

The advantages of continuous filament yarn are no fuzzing, and a bulkier hand. Continuous filament yarn has a bulkier feel because of the fiber crimping method associated with bulked continuous filament.

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Fiber 101

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1st Generation Yarn was extruded as a round fiber like spaghetti. This shape would magnify any soiling, so the yarn looked dirtier than it really was. (Developed in the late 40's early 50's).

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2nd Generation Yarn was extruded into a trilobal shape - much like a three leaf clover or square shape with 4 holes running the length of the fiber. These shapes would refract the light, and therefore, hide the soil. Hence, these nylons became know as soil-hiding nylons. In fact, manufacturers of nylon claim these shaped fibers can hide a pound of dirt in one square yard of carpet. (Developed in the late 50's).

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3rd Generation Yarn evolved as the result of static electricity. In the good old days, prior to “anti-static yarn”, one could sneak up on a friend, touch them on the ear or end of their nose, and watch them jump from the shock. A carbon filament, coated in the nylon, was added to the fiber mix to help disseminate and reduce the charges of static build-up. Third generation yarn became know as “static resistant yarn.” (Developed in the late 60's).

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4th Generation Yarn was developed to enhance the soil resistant properties of nylon. This soil treatment enhances the dry soil removal from the fibers when the carpet is vacuumed or cleaned. Fourth generation yarn added the characteristic of “soil resistance.” (Developed in the middle to late 70's). 3M Scotchgard or Invista (Dupont) Teflon

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5th Generation Yarn was developed to reduce staining of the fiber by normal household liquids. The stain treatment is applied after dyeing. Dyeing nylon is a chemical reaction. There are a finite number of chemical sites or “dye sites” on each fiber. When a carpet is dyed, the darker colors use up more of these dye sites. The lighter colors leave many dye sites unused. The stain treatment acts as a clear dye to cover or fill more of these open dye sights. Open sites, if left un-dyed, will provide sites for staining to attach. This does not completely make carpet stain proof but the result is significant. (Stain treatment is perhaps the biggest innovation in the carpet industry. Stain treatment was developed in the middle 80's by Dupont. Because it was the same basic process as tanning hides in Europe Dupont could not patent the treatment).

Stainmaster (Dupont) Invista

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• Tactesse – (BCF & Staple) Invista (DuPont)• Lisse (Mohawk Soft Fiber)• Durasoft (Solutia Soft Fiber)

Fiber 101

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Why do you need to understand fiber/yarn processing?

•65% to 75% of carpet cost is in the fiber/yarn•The majority of carpet aesthetics are set in fiber/yarn construction.

An Introduction to Yarn Processing

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Fiber Extrusion

Five major fiber types:1. Nylon BCF fiber (Continuous Fiber length)2. Nylon staple fiber (Discrete fiber length)3. Polyester staple fiber (Discreet fiber length)4. Polyester continuous filament5. Polypropylene BCF (Solution Dyed; Continuous fiber

length)

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The major nylon fiber suppliers:

• Invista (Formerly Dupont) ( Major BCF supplier)• BASF (Large commodity BCF, very little staple)• Solutia (Major staple supplier)

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Other Suppliers:

• Polyester suppliers: Hoechst Celanese & Recycled plastic bottles (In-house at Mohawk)

• Polypropylene (Olefin): Done primarily internally at Mohawk

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• Staple fiber: Lower cost, wool look, more uniform. (I do not sell staple because it fuzzes.) Dumb statement!!

• BCF fiber: Higher cost, more bulk/value, less uniform

Fiber and Cost/Aesthetics

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BCF Preferred in:Low to medium weightsHigh luster end usesMulticolor end usesHigher apparent valueHigh twisted frieze products

Staple Preferred in: Medium to High weights Subdued luster end uses Solid colors Uniformity (Blending) Lower cost Lower end price sensitive products

BCF Versus Staple - Residential

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BCF Nylon yarn processing is a two-step process:1. Cable twisting (Two plies yarn with a fixed twist per

inch)2. Heat-setting (Uses heat/steam to set twist)

Yarn processing

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• Sets in twist memory• Makes the dye uptake more uniform • Makes the bulk memory more uniform • Sets texture

Purposes of Heat-setting

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Yarn size• Spun yarn• Constructed during yarn processingFiber luster• Bright fiber (residential)• Semi Bright• Semi-dull• Dull (Titanium Dioxide, white paint pigment

mixed before extrusion to create low luster)Ply twist• Primary performance/value factor• From 3.0 to 8.0 TPI

Yarn Constructing Aesthetics

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TextureCreated by a stuffer box and set in the heat-setting processCan be varied stuffer box gate pressure, twist and steam

The Pilling/Fuzzing/Shedding IssueOccurs with staple only due to discreet fiber length.Can be minimized depending on the following factors:

a. Higher twist yarns d. Good brushing/shearingb. Finer yarn e. Latex encapsulationc. Carpet construction f. Proper maintenance

(Vacuum)

Yarn construction aesthetics

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Twist Configurations

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High twist versus low twistBetter floor performanceLess apparent value in carpetBetter tip definitionLess luster with smooth surfaceCan become so high that kinks beginLess processing problems:

• Stronger cuts easier• Tighter requires more stitch rate• Harder hand• Better shear-smooth surface

Ply twist and it effects

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Air entangling is an alternative method of combining or “mingling” by a system of high-pressure, intermittent air jets. The tiny filament are intimately blended, mixing pre-colored yarns into a heather pattern. Plying two or more colors will produce a tweed or ‘barber pole’ effect.

Generally used only in loop pile carpet.

Air Entangling

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Tufting

The tufting process begins when measured lengths of yarn are fed off beams or creels to be sewn into the primary backing.

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Important factors in the performance of tufted carpet are:• Gauge• Yarn Type• Face Weight or Ounces• Density• Yarn Twist• Pile Height• Stitches per inch

Tufted carpet

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Gauge: Measures the distance between the needles across the width of the carpet. Gauge is the stated by the distance between the center of the needles.

Fiber Type: Fiber type is divided in two parts.1. Kind of fiber.2. Fiber size or thickness (Denier)

Face Weight or Ounces: Ounces per square yardDensity is controlled by the gauge of construction, the stitches per inch, the pile height and yarn ply twist.Density = 36 X #of oz’s of yarn per square yard divided by the pile height.

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Performance Factors

Yarn Ply Twist: The number of times two or more yarns have been plied or twisted in one inch. Single most important performance characteristic

Pile Height: The length of the tuft from the backing surface to the tip of the yarn tuft.

Stitches Per Inch: Stitches per inch define the number of stitches down the length of the carpet.

Performance Factors (continued)

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Dying

There are several different dye methods. The most common dye methods for residential carpet are:

Solution Dyeing – Solution dyeing is achieved when the color is added to the fiber while in the molten state before extrusion. Since the color penetrates completely through the yarn, this dye method is the most colorfast. (Carrot vs. radish). Olefin can only be solution dyed. Nylon and polyester can be solution dyed or topically dyed.

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Dying

Topical dying is the most common method of dying by applying the dye to the surface of the yarn. Topical dying is a function of two factors, time and temperature. The longer the yarn is exposed in a dye bath and the higher the temperature, the greater the dye penetration. The following dye methods are all topical dying:

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Continuous Dyeing or Range dyeing is also a topical dyeing method. Continuous dyeing is by far the fastest dyeing process. A continuous dye range can dye 50 to 100 feet of greige goods (un-dyed carpet) per minute. About 75% of all residentially dyed carpets are done on a continuous dye range. The speed has helped keep the costs of residential carpet down compared to other household products. Multi-colors, tone on tones, solid colors, and some patterned carpets are dyed on continuous dye ranges

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Dying

Stain Treatments

After dying the carpet a stain treatment is applied. Olefin is solution dyed and does not need nor will accept a stain treatment. Polyester accepts a dye so well that a stain treatment is not necessary.

Nylon, on the other hand, needs a stain treatment to protect a portion of the fiber that did not accept dye. The stain treatment is a clear dye applied immediately after the dyeing process.

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Finishing and Shearing

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1. To lock in the individual tufts (tuft bind) 2. To make the carpet more durable 3. To prevent unraveling 4. To improve resilience 5. To improve sound and thermal insulation 6. To reduce pile shedding (with spun yarns)

Finishing – Why apply backing?

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After backing, the surface pile of the carpet is sheared to remove fuzz and loose fibers. Mechanical drag and abrasion during tufting and dyeing will cause the carpet face be quite fuzzy. Shearing gives an attractive surface appearance to the finished carpet.

The shearing process is also used to produce level tip shear or random sheared carpets.

Shearing is a two-step process that first heavily brushes the carpet pile to make it erect and uniform. The carpet is then passed through a series of blades, which cut the fiber tips at precise, adjustable heights.

Shearing

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Mill Tour Video

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Tom Ramsey

Mohawk University

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From the Beginning

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• What is ceramic tile?• What is natural stone tile?• Where do these material come from?• How long have they been around?• What about today’s market for ceramic tile

and natural stone?

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Ceramic Tile Production Processes

Mining Grinding /Blending Pressing

FiringGlazing Finished Tile

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DVD Time

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Market Trends

A Growing Demand for Durable, Stylish and Easy Care Surfaces

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Easy Care & Maintenance

A Beautiful Investment

Durability

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Types of Ceramic Tile

GLAZED UNGLAZED

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Glazed Ceramic Tile

• Glaze Surface Coating made from glass derivative called “Frit”.

• A Hard, Non-Porous, impermeable surface after firing.

• Does Not Absorb Moisture

• Highly Stain-Resistant

• Scratch and Fade Resistant

• Hygienic & Easy to Clean

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Unglazed Ceramic TileQuarry and Porcelain

• No Additional Surface Applications During Firing

• Consistent Color Throughout the Body

• (Unglazed Only)

• More Dense and Durable than normal Clay Body tile

• Suitable for Interior or Exterior Applications

• Residential or Commercial

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Major Categories of Ceramic

Wall Tile Floor Tile Wall / FloorCombinations

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Wall/Floor CombinationsEnables Customers to Coordinate Tile within a Room.

Available with Coordinating Decorative Trim, Accent and Border Tiles.

Today, many ceramic tiles are manufactured for use on both floors and walls. These floor / wall combinations allow your customer to coordinate the floor and wall tile within a room to achieve a very attractive and consistent look. A variety of decorative trim, accent and border tiles are normally available with these combinations to enhance the beauty even more. We’ll talk more about these design options a little later.

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PorcelainGlazed and UnglazedConsistent Color Throughout the Body(Unglazed Only)• Unpolished,• Polished,• Semi-Polished

Dense, Impermeable Body Resists Moisture < 0.5 W/A %

High Impact Resistance-Will Withstand Years of Heavy Foot Traffic

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Porcelain Tile Body Structure

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Quarry/Paver Tile

• Unglazed, Dense Body

• Natural Slip Resistance

• Used in Commercial Kitchens and Restaurants

• Quarry Tile – Extruded

• Paver Tile - Pressed

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Ceramic Wall Tile

• Less Durable than Floor Tile

• Available in a Semi-Gloss or Matte Glazed Finish

• Suited for Vertical or Countertop Applications

Ceramic wall tile is normally less durable than tile designed specifically for flooring. Most wall tile is glazed with a high-gloss or semi-gloss surface. This glazed, glossy surface has a very low slip resistance, and is very slick when wet. Therefore, glazed wall tile is much more suited to vertical or countertop applications rather than floors.

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Wall Tile Trims

Types of Wall TrimsSurface Trims

Bullnose

Bullnose Corner

2” x 6” – S42694” x 4” – S44496” x 6”- S4669

2” x 2” – SN42694” x 4” – SN44496” x 6”- SN4669

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Selection ProcessRoom Application

Type of Tile to Fit Desired Application

Color and Shade

Texture

Size(s)

Layout Pattern

Trim and Decorative Accents

Grout Color

The above list illustrates the typical selection process recommended for assisting a customer in planning their new ceramic tile installation. However, not all tile performs the same in all applications.

Lets review the specific performance features for each major types of tile in more detail.

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Below the SurfacePhysical Properties of Tile and Stone

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Physical Properties of Ceramic Tile

The ceramic tile industry, like other industries, must conform to a set of quality standards and application ratings. These standards and related tests are established by organizations such as the:• American National

Standards Institute (ANSI)

• International Organization for Standardization (ISO)

• American Society for Testing & Materials (ASTM)

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What About the Performance Ratings ofCeramic Tile?

Scratch ResistanceAbrasion ResistanceBreaking StrengthChemical ResistanceMoisture AbsorptionSlip Resistance

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Scratch Resistance

Tile rated 4 -6 is suitable for Residential Applications

Tile rated 7 or higher is recommended for commercial applications.

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1. Talc Magnesium Silicate Hydroxide2. Gypsum Hydrated Calcium Sulfate3. Calcite Calcium Carbonate4. Fluorite Calcium Fluoride5. Apatite Calcium Phosphate6. Microcline Potassium Aluminum Silicate7. Quartz Silicon Dioxide8. Topaz Aluminum Silicate Fluoride Hydroxide.9. Corundum Aluminum Oxide10. Diamond Carbon

Moh’s Scale

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10 Diamond synthetic diamond 9 Corundum ruby8 Topaz sandpaper7 Quartz steel knife6 Microcline penknife blade5 Apatite glass4 Fluorite iron nail3 Calcite bronze coin2 Gypsum fingernail1 Talc baby powder

Moh’s Scale

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Durability

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Abrasive Hardness Testing

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Breaking Strength of Ceramic Tile

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What about Moisture Factors?

48 Hour Soak Test

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More on Moisture Factors…

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Chemical Resistance

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What about Slip Resistance?

ASTM Test Determines the Coefficient of Friction (COF) Numerical Index Rating

The Higher the COF Index Rating-The Better the Slip Resistance

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More about Slip Resistance . . .Americans with Disabilities Act (ADA) Standard:

COF of 0.6 or Higher

0.8 for Access Ramps to Commercial Buildings

Unglazed Tiles are more Slip Resistant than Glazed Tiles

Abrasive Additives increase COF and Slip Resistance

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Ceramic Tile Identification Labels

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Literature – Sales Sheets

Size/color selling part information gridUsage iconsTechnical Information

Wear Rating (Abrasion Resistance - PEI)

Scratch Hardness (MOHs Rating)

Trim pieces available

Care and maintenance information

Tile thickness information

Grout joint recommendation

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Loose Tile Corner Labels

Color-Keyed Category Identification103

Shade Variations in Ceramic Tile and Natural Stones

Low - Consistent color within each tile and from tile to tile.

Medium – Color variation within each tile

High – Some variation from tile to tile, and within each tile.

Random – Considerable variation from tile to tile.

Low Medium High Random

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Shade

G radePlantCaliberM fg. DateInspector

Carton UPC

Color Description

Internal BarCode

Shape Description

Series Description

Carton UCC

Sales Q ty, UO M ,Pound/Carton,Pieces/Carton

Color Shape

Dal-Tile Standard Carton Label

Hum an Readable(See Detail Below)

% 19990280597855550120117500011BarCode Id Char.M fg DateIref = 059785Shade = 5550CaliberShiftL inePlant

Decode of Hum an Readable= %= 1999028

= 1= 2= 01= 175

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Acceptable Flooring Substrates

• Concrete Slabs

• Plywood

• CBU

• Existing Ceramic Tile

• Existing Vinyl Flooring

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Unsuitable Wood Substrates

DO NOT Install Ceramic Tile or Natural Stone Directly Over:Hardwood FlooringParticle BoardMasoniteChipboardLuanGypsum Floor Patching

Oriented Strand Board (OSB)

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Installations on Drywall Substrates

Use a Polymer-Modified Thin-Set or an Organic Adhesive

Applied Directly to Drywall Surface- Painted or Textured Surfaces (sanded smooth)

NEVER Install Over:

• Wallpaper

• Fabric

• Any Other Wall Covering

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Hardwood

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What makes Hardwood an Attractive Flooring Option?

4. Flexibility

5. Color

6. Beauty

1. Natural Warmth

2.Environmentally Friendly

3. Infinite Variety

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What makes hardwood an attractive flooring option?

Hardwood Flooring adds value to the home!

7.Value

• Oak continues to lead market with 60% share of market Top volume widths:

o 2 ¼” (62%) in solid; 3” (60%) in engineered.

• Growing trend in Domestic exotics Maple, Hickory, Cherry, Walnut, others taking share

• Tropical Exotics still selling losing some share to domestic species oak and exotics

• Wider Width Trend Increasing shift to wider products – driven by retail Maple: 50% narrow/50% wider Other exotics heavier to wide width

• “Glueless” locking systems - Faster, cheaper installations• Growth of high performance finishes

Market Trends

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How long ago was wood used as a flooring choice?• 4,200 years ago *10,000 years ago• 1,600 years ago *1,000 years ago

Survey Said: 1,600 years ago

How old are some of the oldest wood floors that are still in use today?

• 200 years old *300 years old• 600 years old *800 years old

Survey Said: 800 years old

Family Feud

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In the 18th century, how were wood floors finished?• Unfinished *Painted with designs• Waxed *Stained and varnished

Survey Said: Painted with designs

What floor became a rage in the 1920’s?• Parquet *Dark, formal floors• Herringbone *Lighter-colored woods

Survey Said: Lighter-colored woods

Family Feud

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What was a common choice for flooring from 1945 to 1965 for new home construction?

• Carpet *solid wood • Linoleum *Tile

Survey Said: Solid woodIn the 1950’s what caused carpet to be the flooring of

choice?• FHA approved carpet *The price of new carpet• Easier installation *Carpet performed better• Survey Said: FHA approved carpet*The price of new carpet

*Easier installation

Family Feud

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•Most popular is “Red Oak Natural”•Darker colors for Formal or Traditional•Lighter colors for Country, Casual, Contemporary•Domestic Species•Imported and Exotic Species

Wood Floors and Fashion

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Hardwood SoftwoodSolid EngineeredUnfinished Pre-finishedPlank StripNail/Staple Glue/FloatSquare Edge Rounded Edge

Wood Flooring in Two’s

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•Hardwood Trees, “Deciduous”

•Softwood Trees, “Conifers”

Types of Trees

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Hardwoods

•Flowering Plants / Seeds produced in Fruits

• Broad Leaves with Netlike Veins

• Many are deciduous (Oaks, Elms, Maples)

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http://www.oardc.ohio-state.edu/visitor/images/trees.gif



Softwoods

•Needle and/or Cone bearing trees

•Conifers are Pine, Cedar, and Fur

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http://www.epa.gov/maia/images/md-trees.jpg

http://www.epa.gov/maia/images/md-trees.jpg

Cells & Rays

•Most of the cells in wood are arranged parallel to the long axis of the tree. They are hollow, water conducting and support cells.

•Ray cells are aggregations of cells extending radially from the bark to the inside of the tree.

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•Bark•Cambium•Sapwood•Heartwood•Core - Pith

Tree Parts

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Janka Hardness RatingMeasures the force in PSI required to embed a .444-inch steel

ball to half its diameter into wood.

Measuring the Hardness of Wood

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Pecan 1820Hickory 1820Maple 1450Oak (white)1360Ash 1320Beech 1300Oak (red) 1290

Yellow Birch 1260Yellow Pine 870-690Black Walnut 1010Black Cherry 950Heart Pine 1225Fir 660

Wood Flooring Hardness Scale(Dent Resistance in PSI)

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Heartwood

•The central core of wood in mature stems that no longer conducts sap and has no living cells.

•In most species, infiltration of minerals imparts a noticeably darker color to this wood.

•Because of minerals present in the cell walls heartwood may also be more stable, less susceptible to decay and more dimensionally stable.

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Sapwood

Sapwood is the softer, younger, outer portion of the tree that lies between the cambium (formative layer just under the bark) and the heartwood.

It is more permeable, less durable, and usually lighter in color than the heartwood.

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Sources of Wood VariationGenetics – trees are living individuals.

Environment – did it grow up on a north or south facing slope, a wet valley or a dry mountain top?

Position within the tree – Heartwood or Sapwood.

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•Plain sawn expands more in width•Quarter sawn more in height•Relative humidity range of 30-50%•Temperature of 60-80 degrees•Dimensional change varies by species

Wood Floors and Moisture

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These numbers indicate the relative tangential (sideways) shrinking or swelling within normal moisture content limits of 6-14 percent.

To find the amount of shrinking or swelling for a particular species, multiply the change in moisture content by the “dimensional change coefficient.”

Then, multiply that answer (product) by the board’s width.

Dimensional Change Co-efficient

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Example: A red oak (change coefficient = .00369) board 5 inches wide changes its moisture content by 3 percentage points -- from 6 to 9%.

3 x .00369 = .01107 x 5 inches = .055 (1/16) of inch per board in width

In reality, the boards will not expand quite that much, because pressure from the adjoining boards will restrain some lateral movement.

Wood can hold as much as 25 - 30% moisture content. That’s the fiber’s saturation point.

Dimensional Change Co-efficient

132

Wood flooring performs best within a relative humidity range of 30 to 50% and a temperature range of 60 to 80 degrees F. Fortunately, that’s about the same comfort range most humans enjoy. How much would a roomful of boards expand or shrink across their width? The amount may surprise you. Example: 5-inch red oak planks are laid 10 feet across a room. At 70 (F.) and 40% relative humidity, each plank has 7.7% moisture and measures 5 inches. If humidity falls from 40% to 20%, the moisture falls to 4.5%. Each board shrinks by .059 inches. Across the room, the floor shrinks 1.4 inches. If humidity rises to 65%, the moisture content rises to 12%. Each board expands by .075 inches. Together, the floor widens by 1.9 inches.

How much will wood expand across a normal room?

133

Can consumers avoid expansion and shrinkage problems?No. They can’t avoid swelling and shrinking. However, they can minimize it and the consequences of buckling boards, by letting the wood sit in their house for several days before installing them. It’s called “acclimating” the wood to the environment.

To help your customers understand the power that expanding wood can exert, you may recite these examples

Wood Expansion

134

Dimensional Changes

Solid

Engineered

Up to 12% change

Solid flat sawn wood – majority of expansion is in the width

Engineered wood expands the same percentage in each direction – but less overall

Less than 1% change

Less than 1% Change

Less than 1% change

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Wood Flooring Types

EngineeredEngineered

SolidSolid

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Solid Hardwood Flooring

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•Unfinished and pre-finished•Usually ¾” thick•About 1/8” wear layer•Solid wood is cut from tree with saw

Solid Wood Flooring

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Solid Wood Flooring

139

Plain Sawn - Tangential Most common, least expensive, softest grain construction, grain mostly goes across the board.

Quarter Sawn - Radial Costs more, grain goes through the board, harder grain construction.

Cuts for Solid Hard Wood

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Radial Vs. Tangential

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Engineered Flooring

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Three PliesFive Plies

Cross Grain Construction

143

Glued Under Heat & Pressure

COR

E

FACE

BOTTOM

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Multi-Ply Cross-Grain Construction3 ply or 5 ply construction More stable than solid wood floors Guaranteed to maintain its shape

Engineered Wood Product Construction

145

Top Veneer Approximately ¼ inch thick (sliced) Northern or Southern hardwood Most popular Species for Engineered are Oak and

MapleOther Veneers North American hardwoods Softwoods

Engineered Wood Product

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Sliced

Rotary

Sawn Veneers

Top Veneer Cutting Methods

147

Solid Construction• On or above grade• Higher raw material cost; lower mfg.

cost (compared to engineered flooring)

• Traditional look• Refinish opportunities• ¾” requires a wood/wood composite

sub-floor for nailing• Available pre-finished or unfinished• NO RADIANT HEAT APPLICATIONS

148

Engineered Construction

• Below, on or above grade• Cross ply construction increases

dimensional stability• Lower raw material cost; higher mfg.

cost (compared to solid flooring)• Install over a variety of sub-floors• Usually pre-finished but available

unfinished• BEST FOR RADIANT HEAT (specific

products)

149

Reasons for Engineered Sales Growth

Installation flexibility Glue directly to concrete Install almost anywhere in the

home (basements) Advent of stapling technologyoSpeed of installationoReduction of installed costs

(staples vs. adhesive)oAbility to install over less

costly sub-floors (OSB)

150

•Dimensionally Stable•Can be installed over most sub floors•Suitable for all grade levels•Can go over Radiant Heat•Minimum acclimation•Little or no expansion joints required

When Do I Use Engineered?

151

•On or above grade only•Requires expansion space•72 hours acclimation time•Staple and Nail Only

When Do I Use Solid?

152

Importance of Species

75% VISUAL75% VISUAL

25% PERFORMANCE

HardnessExpansion (dimensional

stability) & contractionOverall Stability

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•Strip – less than 3 “•Plank – 3” or more•Parquet – small pieces grouped together

Styles of Wood

154

Edge Treatments

Square Edge Eased or Beveled Edge & Kissed

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Square edge vs. beveled Square ends and edges tend to be more expensive than beveled – requires

tighter manufacturing controls Heavy beveled costs less in manufacturing Beveled products help hide sub floor irregularities

Edge/End Treatment

156

•Unfinished Wood Flooring•Pre-finished Wood FlooringUrethaneAluminum OxideUV Cured

Wood Floors Product Finishing

With acrylic impregnation

Standard,non-impregnation

157

• Most have some minerals suspended in U.V. cured urethane (often aluminum oxide)

• 10 x higher abrasion resistance than other site-finished urethanes

• Damage requires a board replacement• Less maintenance than wax finishes• Stain/chemical resistance

Factory Finish Urethane

Urethane settles within the aluminum oxide in the finish, so you are actually walking on the top of the aluminum oxide crystals, which protect the floor’s finish.

158

•Quality & consistency of finish•Consistent color•Consistent gloss•UV Cured

•Less dust at install

•More coats applied

•Solid – 6 Coats

•Engineered – 9 Coats

Benefits of Pre-finished Floors

159

• Quality – not as dependent on installer and job site conditions• Time is Money – factory finished installation time is about 1/2 of site-finish• Performance - extended warranties and guarantees on wear layer and finish• Aesthetics – superior finish consistency and gloss level

Summary: Factory vs. Site finished

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LAMINATE FLOORING

162

Laminate Plank ConstructionTransparent Wear Layer, Melamine and aluminum oxide Impregnated; Easy to clean – never needs wax.

Décor paper; design print impregnated with melamine resins.

HDF Core; (high density fiberboard), impregnated with phenolic resins.

Under layer: Melamine impregnated; moisture resistant

163

Melamine Backer- Moisture resistant- Balances the panel

Mohawk Laminate Flooring Components

164

HDF (High Density Fiberboard) Core

- On all Mohawk products• Glued ‘watertight’• Consists of wood fibers and high

quality synthetic resins• Low flammability

165


Decór layer - Colorfast- In-house development- Use of different design patterns per

product type- Use of different color prints per

product type

166


Overlay with Aluminum Oxide• Very stain, wear, impact and

scratch resistant• Hard to inflame (cigarette burn

resistant• Resists household chemicals• 100% transparent• Aluminum oxide – 2nd in hardness

to diamonds

167


When were laminate floors introduced?• 1950’s *1960’s• 1970’s *1980’s

Survey Said: 1970’s

Where was laminate first used?• USA *China• Europe *Russia

Survey Said: Europe

Family Feud

168

What company brought laminate floors to the USA?• Unilin *Witex• Pergo *Armstrong

Survey Said: PergoWhat made laminate floors’ growth explosive?• Price *Durability • Ease of Installation *Maintenance

Survey Said: All of the above

Family Feud

169

When did laminate become popular in the USA?• Early 1990’s *Late 1990’s • 1980s *Early 2000

Survey Said: Late 1990’sWhat company introduced the glueless

installation?• Pergo *Unilin• Witex *Armstrong• Survey Said: Unilin

Family Feud

170

U.S. Laminate Evolution

1950’s

High PressureLaminate(HPL)developed for furniture applications.

1980’s

Laminate flooringdeveloped by Perstorp as newapplication for HPLlaminate

1989

Pergo becomesfirst significant dedicated laminate flooring company

Early ’90’s

European wood panel mfrs enter laminate business

Mid ’90’s

Laminate flooring intro’d in North America by Pergo. Other European & US mfrs follow.

2000’s

Boom of Uniclic Installation System

Unilin’s DPL technology successfully challenges HPL

171

The Angling Method The Sliding or Snapping Method

Unilin’s Uniclic®

172

Laminate Basic Characteristics

No Wear

No Stain

No Fading; No sun Bleaching from UV

light

Cigarette Burn Resistant

Static Loads in Excess of One Ton

G-44The Product

173

•Will not wear out.

•Never needs refinishing.

•Will not stain.

•Will not fade.

•It is easy to maintain

Laminate is growing because it:

174

The one-step ProcessI. Flooring production

G-48The Product

The One Step process; DPL Product Flooring laminate a. Overlay b. Decor paper c. Core paper

Laminate flooring 1. Flooring laminate 2. Glue 3. Core 4. Glue 5. Backing material

175

DPL: Direct Pressure Laminate (Advanced, 1-step process)

Layers are assembled all at once & pressed together in one single step under high temperature and pressureCoreboard is HDF (High Density Fiberboard) Benefits:

Less raw materials- Perfect melamine adhesion on support- Better balance and dimensional stability

176

Vertical integration enables: • Quality control of all key

steps in the production process.

• Closer interaction between production and R&D.

• Sustainable development and introduction of new products.

• More competitive cost structure.

177

1. In-house HDF production

178

Classification of Laminate Flooring: Residential

Bedroom

Living Room, Entrance Hall

Living Room, Entrance Hall, Kitchen

179

Classification of Laminate Flooring: Commercial:

Bedroom, Hotel, Conference Room, Small Office

Classroom, Small Office, Boutique

Corridors, Shops, School, Multi-purpose Room, Office

180

181

• Swelling percentage of the HDF core board• Anti-Static• Sound properties• Locking system

By which standards is manufacturing governed?

182

•Dent resistance is 1.5 times better than vinyl.•Impact resistance is better for laminate. •Abrasion resistance is better.•Heat resistance exceeds all sheet vinyl.•Chemical and stain resistance is the same as vinyl with urethane wear layers, and better than vinyl and vinyl composition tile without urethane wear layers. •Laminates exceed the scratch resistance of vinyl by two times

How does laminate compare with sheet vinyl?

183

•Laminate is 3-5 times stronger and 10 times less brittle than ceramic tile.•Laminate is 10 times more resistant to breaks or cracks due to falling objects.•Ceramic tile does not burn.•Slip resistance with rubber contact material was about the same.

How does laminate compare with ceramic tile?

184

•Laminate’s surface is harder than that of acrylic or urethane coated engineered hardwood, but about the same as the wood finish of aluminum-oxide impregnated polyurethane•Laminate has greater impact resistance. •Scuff resistance with laminate is better than acrylic-finished wood floors.•It takes 2-3 times more force to scratch laminate flooring.

How does laminate compare to natural wood flooring?

185

Floating Floor System Requires ½ Inch Gap

186

• Adds a cushion that makes walking more comfortable

• Muffles sound• Improves the floor’s resistance to dents• Evens out minor irregularities in the sub-floor• Provides thermal insulation for both heating and

cooling.

The Foam Cushion

187

• Some floors may require a vapor barrier, especially those “below grade” (below ground level) or over cement floors. The vapor barrier is a polyethylene film, installed under the foam.

• Warn the customer that he can’t use poly film over wood, particleboard or other organic materials.

The Foam Cushion

188

• Underlayments level any unevenness in the subfloor.

• Underlayments provide a barrier to moisture coming from the subfloor.

• Underlayments reduce sound transmitted to the floor below and in the room.

• They are required under the Mohawk laminate flooring warranty.

Reasons for Using Underlayment

189

Transmission SoundTo reduce the noise from walking that is transmitted to the room below and that could be disturbing to the persons underneath.

oTo reduce this you need more air in between the floor and the subfloor.

Reflection Sound

The noise that one hears while walking on the floor and IN THE ROOM itself.oTo reduce this you need more mass in

between the floor and the subfloor.

Sound Reduction

190

Uniclic® technology Angle Installation

1. Short End

2. Long End

191

Uniclic® angling method

192

Uniclic® sliding method

193

• It’s easier to maintain

• It’s fade resistant

• It’s easy to install

• It’s dent resistance

Turn Features into Benefits

194

• Vertical integration & manufacturing excellence• In- house MDF/HDF production• In-house impregnation• In house presses• In-house cutting, milling and packaging• In-house distribution

• Innovation

• Branding

Why Mohawk-Unilin Laminate?

195

•Warranties

•Up to 25 year residential wear warranty

•Up to 5 year medium commercial wear warranty

•Commercial AC4 wear rating

•Random or Registered embossing

•25 year water resistance warranty (When installed with

Mohawk underlayment)

•Anti-static and hypoallergenic

Why Mohawk-Unilin Laminate?

196

Vinyl Flooring Product Knowledge

197

$2 billion dollar per year businessComprises 14% of residential flooring

business

Excellent value for your dollarThe most styling options

Vinyl is Alive and Well!

198

• Wide array of patterns, textures, and colors• More Soft & resilient than other hard surfaces• Highly stain resistant• Moisture resistant• Insulates and absorbs sound• Exceptional performance in high traffic areas• Easy to care for• A floor for any budget

Advantages of Vinyl

199

• Carrier for product• Typically 15 - 25 mils thick (1 mil = 1000th of

an inch)• Made of cellulose, fiberglass, latex & fillers• Must be smooth, clean surface• Sealed with coating for biocide protection & to

prevent & minimize felt dirt.

Rotogravure Process – The Felt

202

felt

• Surface you print on

• Must be smooth, clean surface

• Gives floor its “resilience” and “cushion”

• Final thickness (after expansion) ranges from 20-35 mils

Rotogravure Process –Pre-gel Coating

203

feltfelt

Pre-gelPre-gel

Rotogravure Process - Printing

204

FeltFelt

PatternPattern

Pre-gelPre-gel

• Printing Inks (water based Inks today)Two Types1. Embossing (chemical retardant)2. Non-embossing

• Inks provide more than just color• Alkali resistance• Rub resistance• Light and heat stabilities (fade less)

Rotogravure Process - Printing

205

FeltFelt

PatternPattern

Pre-gelPre-gel

Rotogravure Process – Adding The Wear-layer

206

feltfelt

patternpattern

pregelpregel

wearlayer

Urethane• Applied as a top-coat and UV cured• High performance wearlayer• Excellent stain & scuff resistance• Easiest floor to clean• No waxing or buffing needed• High-medium-low gloss range

Aluminum OxideNylon

Vinyl Excellent stain resistance Easy to clean Excellent long-term gloss

retention Worn areas can be buffed

Wearlayer Types

207

Rotogravure Process - Fusion

208

patternpattern

feltfelt

CUSHIONCUSHION

wearlayer

Inlaid ProcessThe Carrier Back

209

Carrier

We begin with a carrier belt

210

Inlaid ProcessApplying the Chips

belt

Q Q

211

Inlaid Process: Thru Chip Pattern

Carrier

Chips

212

Inlaid ProcessCalendaring

Calendars or Rollers

Q

213

Inlaid Process adding the Wear-layer

Felt Chips

Wearlayer

• Higher cost to manufacture

• Material itself is heaver to handle

• Available mostly in six foot widths

• Difficult to seam

• Completely different look than rotogravure

Inlaid Product

214

Rotogravure - Design is printed with inksMore cost effective12 ft. widths - fewer seams

Inlaid - Color chips are deposited on a sheet“Thru” chip colorCompletely different look than rotogravure

Inlaid vs. Rotogravure

215

Tile

Sheet Vinyl

Styles of Resilient Floor-covering

216

VCT Tile Line

218

Q

Q

Q

Calendars

Press

Stacker

Chips from chip linePolish Application

• Comes in 6’ and 12’ widths with some 15’

• Rotogravure (Printed) usually 12’ or 15’

• Inlayed (Thru chip patterns) usually 6’

Sheet Vinyl Flooring

219

Overall thickness helps with Resistance to indentations More cushioning under foot Dampens noise & more insulation

Wear-layer types and thickness Urethane is stronger than (PVC) Aluminum oxide is very scratch resistant Nylon also adds to the scratch resistance

Walk-off mats

Vinyl Performance

220

Full Spread (Most Common)

Perimeter Glued

Loose Laid or stapled

Vinyl Installation Methods

221

Thank you

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Questions?

222

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