HomeMy WebLinkAbout16036_PCA Inter_VM 20121119
Via FedEx
November 19, 2012
North Carolina
Department of Environment and Natural Resources
Brownfields Section
1314 Mallard Ridge Rd
Tega Cay, SC 29708
Attention: Ms. Carolyn Minnich
Re: Vapor Mitigation System Design
Former PCA Facility
815 Matthews-Mint Hill Road
Matthews, North Carolina
H&H Job No. HTE-003
Dear Carolyn:
On behalf of Matthews Property 1, LLC Hart & Hickman, PC (H&H) is presenting the attached
vapor mitigation system design for the basement area of the former PCA facility located at 815
Matthews-Mint Hill Road in Matthews, North Carolina.
The former PCA facility was recently purchased by Matthews Property 1, LLC and encompasses
approximately 16 acres with an approximate 164,000 square feet (ft) industrial building
containing offices, former production areas, and warehouse/storage areas. A site layout is
included as Figure 1. The enclosed vapor mitigation system and flooring plan has been prepared
for a portion of the facility (identified as the basement area) that was previously utilized for the
storage of photograph development compounds and solutions, a silver reclamation system, and
management of the wastewater derived from the photograph developing process. Matthews
Property 1, LLC plans to up-fit the basement area space for future use as storage, primarily for
HVAC equipment.
H&H previously completed indoor air sampling in the former PCA building, including the
basement area, in August 2012. In the initial sampling event when there was no active
Ms. Carolyn Minnich
November 19, 2012
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ventilation in the building, concentrations of ammonia and formaldehyde were detected in indoor
air above conservative Department of Environment and Natural Resources (DENR) screening
levels based upon a LICR of 1 x 10-6 and a HI of 0.2 in the basement area. In a subsequent
sampling event conducted when air handlers were operated in the building (although the HVAC
systems were not fully operational), concentrations of ammonia and formaldehyde were lower,
and only concentrations of formaldehyde were detected slightly above the conservative screening
levels.
An evaluation of calculated cumulative potential carcinogenic and non-carcinogenic risks for
each of the sample locations indicated that the calculated cumulative risks for the sample
locations from both sampling events were in the range of LICR of 1 x 10-5 and did not exceed 1 x
10-4, which is the level where potential mitigation might be performed. Several locations in both
sampling events slightly exceeded a HI of 1; however, these detections appear to be associated
with the storage of the plastic piping and boxes in and near the warehouse area. No compound
concentrations at any sample location exceeded occupational exposure levels.
Because there is a faint odor of ammonia in the basement area under certain conditions and soil
below the basement area is known to be impacted and contain ammonia odors, Matthews
Property 1, LLC has elected to install an active vapor mitigation system and PVC-based flooring
material in the basement area as a conservative measure. As is detailed in the enclosed vapor
mitigation system design drawing, the planned vapor mitigation system will include the
following:
H&H will provide oversight of system installation and will provide a PE certification of
system installation after completion.
Vapor collection piping will be installed in trenches formerly utilized in the silver
reclamation wastewater management system in the basement area. The vapor collection
system piping will be tied into a main header connected to a piping run routed to a
Ms. Carolyn Minnich
November 19, 2012
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vacuum fan mounted outside of the building. The vapor mitigation system will extract
vapor from the collection piping network in order to depressurize the sub-floor area and
mitigate potential vapor intrusion into the up-fitted basement space from the sub-floor
area.
Permeable stone will be placed in the trenches around the piping, aggregate material will
be placed within the trenches over the stone, and leveling cement will be installed within
the trenches above the aggregate material.
Leveling cement will be installed (as needed) to level the existing basement area surfaces
and filled trenches to prepare a suitable sub-floor surface for installation of flooring
material.
Protect-All® commercial flooring will be installed in the basement area over the basement
sub-floor area. The Protect-All® commercial flooring product is a 0.25-inch (250 mil)
PVC-based material that will be professionally installed in accordance with manufacturer
recommendations including welded seams and sealing around penetrations. The Protect-
All flooring will be functionally equivalent to an impermeable liner overlying the active
mitigation system. We have enclosed a copy of the Protect-All® Commercial Flooring
Installation Manual for your reference.
Please also note that Matthews Property 1, LLC will also be removing porous material from the
basement area including ceiling tiles and ceramic tiles on the walls of the basement area, and
sealing the fireproofing material on the ceiling of the basement, all of which could also
potentially be contributing to odors and/or ammonia concentrations in the basement area.
After completion of the vapor mitigation system installation, removal of porous materials in the
basement and other materials of the building, and up-fit of the HVAC systems at the facility,
Matthews Property 1, LLC will perform follow-up indoor air sampling for ammonia and
Ms. Carolyn Minnich
November 19, 2012
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formaldehyde in a similar manner as was conducted during the previous indoor air sampling at
the facility.
Matthews Property 1, LLC would like to begin work on the mitigation system installation as
soon as possible. If you have any questions or comments, please do not hesitate to contact me.
Sincerely,
Hart & Hickman, PC
Steve Hart, PG
Principal
Enclosures
Former PCA Facility
C b F ilit
y
Conbraco Facility
Basement Vapor
Mitigation Area
TITLE
PROJECT
SITE LAYOUT
FORMER PCA FACILITY
MATTHEWS, NORTH CAROLINA
N
2923 S. Tryon Street, Suite 100
Charlotte, NC 28203
DATE:
JOB NO:
REVISION NO:
FIGURE NO:
11-15-12 0
1HTE-003
,
704.586.0007(p) 704.586.0373(f)
1
Installation Manual
September 2011
Oscoda Plastics®, Inc.
5585 North Huron Ave.
Oscoda, MI 48750
800-544-9538 Phone
989-739-1494 Fax
www.oscodaplastics.com
2
Contents
Installation Quick Tips 3
1. Before You Start 4
2. Definitions 4
a. Grade Level 4
b. Sub-Floor 4
3. Interior and Exterior Preparations 4-6
a. Wood Sub-Floor 4
b. Concrete Floor 5
c. Radiant-Heated Concrete Floor 6
d. Existing Flooring 6
e. Metal Floor 6
4. Design, Layout, and Installation 7-18
a. Tools and Equipment 7
b. General Guidelines 7
c. Applications 8-18
i. Loose-Lay Installations 8
ii. Fully-Adhered/Dry Areas 10
iii. Fully-Adhered/Wet Areas 10-17
1. Radius Weld Method 10-15
a. Tools and Material 10
b. Cove Base 10
c. Dry-Lay 11
d. Cove Base Installation 11
e. Corner Guard 13
f. Welding 13
g. Splicing Radius Welding Rod 13
h. Stainless Steel Drain Rings 14
i. Stainless Steel Transition Strips 14
j. Adhesives 14
2. V-Weld Heat Welding Techniques 15-18
3. Cove Cap/Z-Bar 17
4. Stainless Steel Corner Guards 18
5. PROTECT-ALL Adhesives 18
6. Maintenance and Care 19-21
a. Cleaning Heavy Grease and High Traffic Areas 19
b. Cleaning PROTECT-ALL Gloss Products 20
7. Detail – Cove Cap Radius Weld Z-Bar 22
8. Detail – Drain 23
3
Installation
Quick Tips
If you have never installed PROTECT-ALL® Commercial Flooring contact Oscoda
Plastics®, Inc. for training.
A vapor barrier (10 mil) must be installed under a concrete slab.
Proper moisture tests need to be conducted to maintain warranty. Relative humidity is
slab should be under 75% and this test should supersede 3lbs./1000 sq.ft./24hrs. for the
Calcium Chloride Test.
All coatings and curing compounds need to be removed from the slab.
The sub-floor needs to be cleaned of all foreign debris and dirt.
Always use new v-notched trowels to spread adhesive. ⅛” v-notch for ¼” material.
Floor sheets should be acclimated (36-72 hrs.) on site, cut and dry-fitted to perimeter
walls, and all penetrations cut out (drain areas routed-out) before adhesive is applied to
substrate.
Flooring should be set into Oscoda Plastics’ adhesive immediately.
A 100lb. roller is required to roll the flooring into the adhesive.
Correct V-welding temperatures will be determined by a visible wash on each side of
weld rod, fusing of the floor surface near grooved weld zone, and the flow of weld rod
fusing into bottom of grooved joint. Calibration of the heat gun is required. Test-weld
samples of ordered sheet material and V-weld rod daily before any finish welding
begins.
Maximum speed of V-welding should be between 1-½ and 2 linear feet per minute for v-
rod.
Failure to follow all of the Oscoda Plastics’ installation instructions and use of all the
required system components will void the manufacturer’s warranty.
4
1) Before You Start
This installation manual is designed to assist the professional installer by presenting them with
the unique characteristics of PROTECT-ALL Commercial Flooring products and PROTECT-ALL
installations.
A PROTECT-ALL flooring installation requires safe work habits in a safe environment. Installers
should review and follow all safety and health information available such as Material Safety
Data Sheets (MSDS), labels, instructions, specifications, and other pertinent publications.
The installation of PROTECT-ALL should be performed by a professional flooring installer,
familiar with PROTECT-ALL’s unique characteristics, local building codes, and ASTM
Standards. This installer should have at least four years of sheet vinyl and heat-welding
experience. Oscoda Plastics recommends that the professional installer attend and pass
the manufacturer’s installation training class prior to any wet area installation (such as
commercial kitchens). Contact Oscoda Plastics at 800-544-9538 for complete details and
eligibility requirements.
2) Definitions
a) Grade Levels
i) Suspended – A suspended floor is one with a minimum of 18” of well-ventilated air
space below.
ii) On-Grade – An on-grade floor is one in direct contact with the ground or over filler
that is in direct contact with the ground. A concrete slab on ground level is an
example of this type of floor.
iii) Below-Grade – A below-grade floor is partially or completely below the surrounding
grade level in direct contact with the ground or over filler that is in direct contact with
the ground. NOTE: On-grade and below-grade floors should have vapor barriers
installed under the concrete slab.
b) Sub-Floors and Underlayments
i) Sub-Floor – A sub-floor is selected for structural purposes and is the substrate for
the underlayment.
ii) Underlayment – The smooth and level surface used as the substrate for the floor
covering.
iii) Sub-Floor/Underlayment Combination – A surface that must meet structural
requirements as well as have a smooth and level surface for the floor covering.
3) Interior and Exterior Preparations
Oscoda Plastics recommends installing PROTECT-ALL flooring only over structurally-
sound, clean, dry concrete or concrete board (½” minimum), or underlayment grade
plywood. Installing over other substrates and/or existing finishes is at the sole discretion
of the installer and end-user. Oscoda Plastics does not warrant the performance of any
installation not recommended in this installation manual.
a) Wood Sub-Floor Preparation
5
i) PROTECT-ALL flooring can be installed over suspended wood sub-floors. On-grade
or below-grade installations will be at the discretion of the installer and end user and
are not recommended.
(1) ¾” marine-grade plywood is recommended for the finished sub-
floor/underlayment in cooler and freezer areas.
ii) Sub-floor panels, strip wood, board or plank-type sub-flooring may require covering
with an underlayment. Wood underlayments should be structurally-sound, designed
for resilient flooring underlayments purposes. Panels should be clean, free of any
dirt, wax, oil, or adhesive residue. All wood underlayments/sub-floors should be solid,
well nailed at the joints, and free from movement. Reference ASTM F1482, Standard
Practice for Installing and Preparation of Panel Type Underlayments to Receive
Resilient Flooring.
iii) Old wood floors to be covered should be stripped of paint, varnish, wax, oils, and
adhesives. If this is not possible, then cover with an appropriate underlayment.
NOTE: Luan products are NEVER recommended for use under PROTECT-ALL
flooring.
iv) Floors drains, of any type and size, should be properly sloped prior to PROTECT-
ALL being installed.
v) Prior to beginning the installation, always broom sweep and shop vacuum to ensure
that all dust and debris has been removed.
b) Concrete Floor Preparations/Testing
i) ALL on-grade and below-grade concrete floors should have an existing vapor barrier
(10 mil/0.010 in.) installed below the slab. Consult the following standards; ASTM
E1745-97, ASTM E96-00, ASTM E1643, and ACI 302.1R (www.astm.org and
www.aci-int.net). The concrete sub-floor should be dry, smooth, and structurally-
sound. It must be flat (FF20) and level (FL15), except for sloping to drains. It should
be free of depression, scale, and foreign deposits of any kind. Paint (any type),
varnish, oil, wax, stain, and old adhesive residue must be removed. Prior to the
installation, the floor should be swept and shop vacuumed to ensure all dust has
been removed.
ii) The following tests should be performed prior to any PROTECT-ALL installation over
concrete: Tests 1, 2, 3, and 4 should be conducted three times in three different
testing areas within the first 1,000 square feet and one test every 1,000 square feet
thereafter. Reference ASTM F710 Standard Practice for Preparing Concrete Flooring
to Receive Resilient Flooring.
(1) Calcium Chloride Test – Required results: moisture vapor emission rate of
3lb./1,000ft2 per 24 hrs. (See 3.b.viii) Consult ASTM F1869.
(2) Relative Humidity Test – Required results: 75%-80% relative humidity. (See
III.B.8) Consult ASTM F2170.
(3) PH Test – Required results: 8 to 10. (See 3.b.viii).
(4) PSI Test – Required results: 3500 psi – minimum.
(5) Adhesion Test – If the results for test 1, 2, and 3 are acceptable, a final
adhesion test is recommended. In an inconspicuous area, a 12” x 12” piece of
PROTECT-ALL should be adhered using the appropriate sub-floor preparations
6
and either the #127 or #139 2-part adhesives. If after 72-hours the 12” x 12”
piece is completely bonded, the concrete sub-floor is satisfactory for a
PROTECT-ALL installation.
iii) Rough, uneven, score marked, cracked concrete (as long as it is structurally-sound)
should be filled using the appropriate filler. Fillers and leveling compounds must
be of a cementitious type (non-gypsum), must be moisture-, mildew-, and
alkali-resistant, and must provide a minimum of 3500 psi. The type of
cementitious leveling compound to use is at the discretion of the installer and end-
user. Adhesion tests should be performed when considering what filler/leveler to use
(see 3.b.ii).
iv) Cement type underlayment boards (minimum ½”) can be used under PROTECT-ALL
flooring as long as they have been installed according to their manufacturer’s full
recommendations.
v) It is not recommended that PROTECT-ALL be applied over expansion joints.
vi) Concrete curing/drying compounds can reduce the adhesion of Oscoda Plastics
specified adhesives. Removal of these products is necessary prior to adhering
PROTECT-ALL. Adhesion tests must be performed prior to installation (see 3.b.ii).
vii) Suspended concrete floors should meet the standard criteria mentioned under 3.b. i-
ix.
viii) If high Moisture Vapor Emission Rates (MVER), relative humidity levels, or alkalinity
levels exist, then a surface-applied vapor reduction system may be needed. If any
moisture reduction system is chosen, it must be compatible with Oscoda Plastics’
#127 or #139 epoxy adhesives, for which all testing should be done by that system’s
manufacturer, not Oscoda Plastics. The moisture/vapor barrier’s performance and
warranty are the responsibility of their manufacturer, end-user, and installer, and not
Oscoda Plastics. Adhesion tests are also recommended with these products (see
3.b.ii). One company, Koester – America, will test adhesives and will warranty
flooring materials and labor with their product system and specified procedures.
ix) Floor drains, of any type and size, should be properly sloped before applying
PROTECT-ALL flooring.
x) PROTECT-ALL should never be installed over gypsum-based sub-floors,
underlayments, or fillers.
c) Radiant-Heated Concrete Floors.
i) PROTECT-ALL flooring may be adhered over radiant-heated floors provided the
maximum temperature of the floor does not exceed 85°F (see III.B. 1-9), and
maximum water temperature does not exceed 110°F.
d) Existing Floors – VCT, resilient (any type), polymeric, quarry, marble, terrazzo,
epoxy, painted, waxed, sealed, stained, and ALL other existing finished floors. It is
not recommended that PROTECT-ALL flooring be permanently installed (with adhesive)
over existing finished flooring of any kind or type. Oscoda Plastics recommends either
completely removing the existing flooring down to the sub-floor or applying an
appropriate underlayment prior to installation.
e) Metal Floors – Metal surfaces require the application of ¾” marine-grade plywood or ½”
concrete board prior to the installation of PROTECT-ALL.
7
4) Layout, Design, and Installation
a) Tools and Equipment: The professional installer should have all the standard tools and
equipment needed for testing and prepping the sub-floor/underlayment, floor layout, dry
fitting, mixing/spreading adhesives, power grooving, heat-welding, and trimming
homogeneous vinyl sheet flooring, base, corners, and trim
i) Unique tools required for PROTECT-ALL flooring:
(1) Electric seam groover (Leister® or Sinclair®1500) – call Oscoda Plastics for
details.
(2) Leister Heat Gun.
(3) Grooving blades including V-groove for V-rod.
(4) Heat welding tips: V-weld tip and radius weld tip.
(5) Skiving trim knife and sharpener.
(6) Electric Drill
(7) Yellow straight-cut and aviation/tin snips.
(8) 1/8” v-notched trowel.
(9) 2 hp (minimum) wood plunge router with ½” straight bit.
(10) 12” metal framing (speed) square.
(11) Metal paddle mixer (for the 2-part adhesive).
(12) Caulking Gun.
(13) Duct tape.
(14) Under scribes.
(15) Hammer.
(16) Electric hammer drill.
b) General Guidelines
i) Oscoda Plastics provides installation classes at its facility in Michigan.
Participation and successful completion of this class is recommended prior to
any first time wet area installation. For more information call 800-544-9538 or
visit www.oscodaplastics.com.
ii) PROTECT-ALL Matte (standard finish) products are designed for areas exposed to
high levels of moisture that require a floor with slip resistance. PROTECT-ALL matt
is also designed for high traffic and heavy-impact areas. Wet areas require the full
“wet system installation” (see 4.c.iii). The manufacturer recommends PROTECT-ALL
installed with the rough side up in areas where people are in their bare feet such as
water parks and shower rooms. Call Oscoda Plastics for details. NOTE: Oscoda
Plastics does not recommend wearing soft neoprene-soled shoes on its
flooring.
iii) PROTECT-ALL Gloss products are designed for “dry areas” only. PROTECT-ALL
gloss must be adhered down using the PA #127 or #139 two-part epoxy.
iv) The installation should not begin until the work of all other trades has been
completed. If the job requirements do not permit this, then cover the floor with ¾”
plywood/OSB to protect the sub-floor, adhesive, and PROTECT-ALL flooring before,
during, and after installation.
(1) PROTECT-ALL flooring is DIRECTIONAL. The 5’ x 8’ and 5’ x 5’ sheets have
arrow stickers on the top of the sheet. Install with these directional arrows all
8
facing the same direction. Leave directional arrows in place until installation is
completed. The 24” square cut tiles have a pen mark on the side of the tile
indicating the machine direction. The 5’ x 8’ and 5’ x 5’ sheets should be laid out
to eliminate four-way corners. A staggered joint is recommended with at least a
12” off set.
v) All exterior PROTECT-ALL installations must be full-adhered using Oscoda Plastics
specified adhesives. Standard floor preparations (3.a-e) apply. Temperature
changes, sunlight, and adhesive cure rates greatly affect exterior installations.
“Tenting” the area to provide constant shading is recommended given the day/night
temperature variables. Install no more flooring that can be adhered, heat-welded,
and allowed to cure within the same day.
vi) PROTECT-ALL flooring can be cut using a standard utility knife. To ensure clean
straight seams, always use a straight edge and change blades often.
vii) PROTECT-ALL flooring should be acclimated to the job site for a minimum of 36
hours prior to installation. The building must be completely enclosed and water-tight.
A/C must be on at least seven days prior to installation beginning, keeping the
interior temperature at 70°F. This temperature should be maintained during the
installation and an additional eight days after installation is completed.
viii) Place curtains over windows and doors to prevent the flooring from being exposed to
direct sunlight during the installation. This will help prevent unwanted expansion and
contraction prior to the adhesive being fully set and cured.
ix) PROTECT-ALL installed with the rough side up requires special hand-trimming tools
to trim the welding rod after heat-welding. Call Oscoda Plastics for details.
x) Weights such as sand bags may be needed at drains, transitions, and slopes while
the adhesives cure.
xi) Additional pieces of PROTECT-ALL may be needed under weight lifting and exercise
equipment, heavy objects, and tires to help prolong the life of the finished floor.
xii) The use of duct tape at perpendicular angles across the seams will help ensure that
ALL seams (flooring, base, and corners) remain tight during the installation and
curing process.
c) Applications
i) Loose-Lay. Before you begin you will need a sharp utility knife, straight edge,
pencil, tape measure, and chalk line.
(1) 18” x 18” Interlocking Tile Installation. The 18” x 18” interlocking tiles should
always be installed in a loose-lay fashion and oriented in the same direction
following the corner with the arrow. The use of adhesives is not recommended.
All standard floor preparations should be followed (see 3.a-e). NOTE:
Interlocking tiles are intended for dry, loose-laid applications and should
never be used as a substitute for permanent flooring in any wet area or be
permanently adhered or chemically-welded at the joints.
(a) Measure the room and multiply with width by the length to find its total area,
(e.g. 12’ W x 10” L = 120 square feet). Divide the total by 2.25 to get the
actual number of tiles needed, (e.g. 120 ÷ 2.25 = 53.33, round up to 54). A
9
cutting allowance of 7 – 10% should be added for rooms over 100 square feet
in size.
(i) To find how many tiles fit in a row, take the width or length measurement
and divide by 1.5 (it is best to round up to the nearest whole number).
E.g. 12’ W ÷1.5 = 8 tiles for width OR 10’ L ÷ 1.5 = 6.67 (round up to 7)
tiles for length.
(b) For best appearance, establish how the tiles are to be set out before starting
the project. The arrowhead corner orientation must be maintained throughout
the installation for proper fit and appearance (see below).
(c) Find the center point of the room.
(i) Measure across the room and mark the center.
(ii) Measure the room in the other direction and mark the center.
(iii) Snap a chalk line across both center points, the intersection of the two
lines (illustrated above as the dotted lines) is the center of the room.
(d) Begin at the center and work out to each wall. Lay tiles in place until the walls
are reached, maintaining the orientation of the arrowhead tile corners.
(e) Cut-offs from one side of room installation (up to 9” wide, for maximum border
width) can be used on the opposite side to fit against perimeter of installation
field (see illustration above, border shaded in gray).
10’ L
12’ W
2.25 Sq. Ft. 2.25 Sq. Ft.
2.25 Sq. Ft. 2.25 Sq. Ft.
2.25 Sq. Ft. 2.25 Sq. Ft.
10
(f) Leave at least a ¼” space at all perimeter walls to allow for expansion and
contraction.
(2) Gym Floor Covers – PROTECT-ALL sheets can be used as a temporary cover
to protect wood gymnasium flooring.
(a) The sheets should be laid out with an off-set joint.
(b) Lay the sheets down so that the seams are as tight as possible.
(c) Removable double-sided tape may be necessary around perimeter to secure
the edges.
(d) When not in use, the sheets should be properly stored and uniformly stacked
with the edges flat and even.
(e) To transport the sheets, custom-made pallets or carts (no more than 30
sheets per pallet/cart) may have to be fabricated by the facility.
ii) Full-Adhered – Dry Areas
(1) Dry area applications are typically NOT exposed to moisture, chemicals, or
standing liquids. The 5’ x 5’, 5’ x 8’, and 24” tiles should be glued down and heat-
welded.
iii) Full-Adhered – Wet Areas Application Methods. Factory training is required. This
application requires the full wet area system to be followed. Manufacturer’s sub-floor
preparations and requirements must be followed (see 3.a-e). PROTECT-ALL gloss is
NOT recommended for exterior applications or interior wet applications.
(1) Radius Weld Method uses flat stock base of ¼” material and heat-welding them
to the floor sheets at the radius transition.
(a) Tools and Materials
(i) Radius Weld Rod
(ii) Radius Heat-Weld Tip
(iii) Wood router with ¾” straight bit
(iv) 8’ Straight Edge
(v) Extra sheets of flat stock to cut base
(b) Measure the lineal footage of base needed and hand cut enough base out of
a 5’ x 8’ sheet to accommodate. One sheet will provide 80 lineal feet if cut at
6” x 8’ – Image 1.
1. Use a 5’ x 8’ sheet, cut into 6” x
8’ strips to create 80 lineal feet
of cove base
1
11
Correct PROTECT-ALL Dry Laid Seams.
No Gaps or Voids.
Incorrect PROTECT-ALL Dry Laid Seams.
Gaps and Voids.
Cross
Section
Cross
Section
14"
(c) After sub-floor preparation is completed, determine the best lay out of the
floor to avoid the need to use small short pieces at termination points.
(d) Install the flooring material using factory recommended adhesive, ensuring
that ALL horizontal and vertical seams (flooring, base, and corners) and cuts
around floor penetrations, perimeter, terminations, etc. fit tight, within 1/16”
tolerance at ALL times. Do not allow gapping or voids between the seams.
PROTECT-ALL welding rod is not designed to fill voids in seams. Door jams,
fixed objects, and floor penetrations, such as plumbing, electrical, and
condensation lines, must have PROTECT-ALL cut-in clean and tight.
(i) The hand cut flat base can be installed immediately over the adhered
sheets.
(ii) Begin installing the base at an inside or outside corner. This is done first
because the base must be wrapped around corners in a continuous
fashion.
(iii) In order to wrap corners with the ¼” material, a relief on the back of the
material is required at ⅛” x ¾” wide. Create this relief by using a wood
router with a ¾” straight bit and a straight edge as a guide – Image 2.
(iv) Using the manufacturer’s specified adhesive, adhere the base to the wall
using a ¼” bead in an “S” pattern – Image 3. A 3” or 4” band of
commercial cove base tape and also be used to adhere cove base –
Image 4.
(v) Immediately hand-roll the base to smooth and set the adhesive. If using
cove base tape, use a rubber hammer to tap cove base against adhesive
backing for strongest adhesion – Image 5.
(vi) Seal the top of the base using the manufacturer’s specified sealant –
Image 6.
2. Make a relief cut ⅛” deep by ¾”
wide.
2
12
(vii) Finish by applying the manufacturer’s universal Z-bar cove cap – Image
7.
3. Adhere using an “S” pattern.
3
4. Adhere using a 3” or 4” band of
commercial cove base tape.
4
5. Immediately hand-roll or use
rubber hammer to set into cove
base tape or adhesive.
5
6. Seal the top of the cove base.
Another continuous bead of
sealant can adhere to top flange
of z-bar if laid ½” – ¾” above.
6
13
(e) Once the base is installed, attach the stainless steel outside corner guard to
help form and adhere the base at the outside corner.
(f) Radius welding can begin once the cove base is attached to the wall. The
radius weld is designed to be completed in a single pass, no grooving
or skiving required. Floor seam welding can only begin with the specified
adhesive has set. Refer to page 14 for details.
(i) Before welding, perform test welds daily to ensure proper calibration of
tools and the correct heat-welding method is performed.
1. Inside and outside corners: 5 – 5 ½ amperage setting with one foot
per minute welding speed.
2. Straight runs: 6 – 6 ½ amperage setting with two feet per minute
welding speed.
(ii) The angle of the gun should always be 45° to the wall/floor. Additionally
the angle of the radius weld tip to the weld rod filling this joint should be
closer to 90° when going into and out of inside cove base corners. This
angle can be greatly relaxed when doing outside corners and straight
welding runs.
(iii) During welding always look for the “wash” at the top and bottom of the
weld rod and the “wave” of melted rod that is pushed ahead of the rod –
Image 8. These two things will confirm that the weld is being performed
properly.
(iv) Weld through inside and outside corners first, at the slightly cooler, slower
speed, 1 – 2 feet away from the corners. Weld straight runs secondly.
(g) When splicing the welding rod:
(i) Hand cut 1” V-notch splice.
7. Attach Z-bar.
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8. Look for the “wash” and “wave”
in the rod.
8
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(ii) Weld the remaining rod into place. Minor trimming and glazing will be
required at all splices and be performed after the rod has cooled. Use of a
straight edge and hoop trimming tool is recommended.
(iii) Double-strike and glaze the finish weld as needed.
(h) Stainless steel drain rings are required on ¼” material to be installed
around ALL floor drains, floor troughs, floor sinks, cleanouts, and any floor
penetration of 3”. Stainless steel drain rings can be purchased from Oscoda
Plastics using the Drain Ring Order Form.
(i) Routering for these drain rings should take place prior to adhering the
flooring down.
(ii) Set the depth of the router (using a straight bit) so that the top of the drain
right is flush with the top of the finished floor. Practice routering on scrap
pieces first.
(iii) Prior to the final mechanical-fastening, apply a ¼” bead of manufacturer’s
recommended watertight sealant under the drain ring.
(iv) Use #10 2 ½” stainless steel screws with lead anchors to secure the drain
rings – Image 9.
(i) Stainless steel transition strips are required at locations where PROTECT-
ALL transitions to another flooring type or is terminating.
(i) Routering for these should take place prior to adhering the floor down.
(ii) Apply a ¼” bead of manufacturer’s recommended watertight sealant
under the strip.
(iii) Use #10 2 ½” stainless steel screws with lead anchors to secure the
transition strips.
(j) Adhesive: Adhering PROTECT-ALL can begin after the floor, drain rings,
and transition strips have been dry-fitted. Be sure to use Oscoda Plastics
specified adhesives for gluing the flooring. Current adhesives used are PA
#127, PA #139, and Eclectic 6100. Follow the recommended mixing
instructions using a ⅛” v-notch trowel.
(i) Mixing should take place over a large disposable tarp.
(ii) Always have a bucket of warm soapy water or mineral spirits available for
spills and clean-up. Unwanted adhesives on top of PROTECT-ALL must
9. Secure drain ring to substrate.
Only use #10 2 ½” stainless
steel screws (tapered head) with
lead anchors.
9
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be removed immediately with the warm soapy water or mineral spirits.
Dried adhesive cannot be removed.
(iii) Roll the floor within 15 minutes using a 100 lbs. roller, and again an hour
later. Rolling should begin in the middle of the sheets moving out towards
the seams.
(iv) Adhesive that is squeezed up through the seams must be clean-up
immediately.
(v) ALL seams must remain tight. The use of duct tape at perpendicular
angles across the seams will help ensure this.
(vi) The adhesive must be allowed to set according to manufacturer’s
recommendation before heat-welding can begin.
(2) V-Weld Heat Welding Techniques. Heat-welding should only begin when the
adhesive has cured (PA # 127 – 12 hours and PA #139 – 6 hours).
(a) Use a power seam groover with an Oscoda Plastics approved grooving blade
set to 1/16” above the surface of the sub-floor – Image 10. Grooving should
be performed so that both sides of the seam have been grooved equally and
uniformly – Image 11.
(b) Seams that the power groover cannot reach must be hand-grooved using a
utility knife and straight edge. Ensure the hand-grooved seam is of the same
depth and width as the power grooved seam.
(c) Set temperature setting on the hot air welder, fitted with heat-welding tips
recommended by Oscoda Plastics. Calibration of the heat gun, amperage
10. Power groove seam 3/16”
deep.
10
11. Finish groove seam.
11
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supply, length of the extension cord, and room temperature may affect the
proper setting. Practice on scrap material first to test settings.
(d) Insert Oscoda Plastics V-Rod welding rod into heat-welding tip and begin
welding the grooved seams at 1 ½ to 2 linear feet per minute. Hold the
heat-welding gun at the correct angle so that the bottom of the tip remains
parallel with the top of the material. Correct heat gun temperature, speed,
and pressure must be maintained to correctly heat-weld PROTECT-ALL.
(i) PROTECT-ALL V-weld Heat-Welding Guidelines:
1. Heat Gun Setting: 6-7 (for Leister Heat Gun).
2. Welding Speed: Approximately 2 linear feet per minute.
3. Heat settings and welding speed may vary, always test equipment
prior to installation.
(e) The correct weld will result in a visible “wash” on both sides of the rod where
the rod contacts the top of the finished floor – Image 12. If the “wash” is not
visible, the weld may be defective and could lead to failure. This “wash” will
be flattened and alongside it, up to ¼” away, the flooring surface will exhibit
fusing (flow). The raised back of the v-weld rod will also show considerable
flattening when the right fusing temperature and speed is attained. Observing
the fusing at weld tip and flow of the weld rod into v-groove is the best
indication that the correct amperage, angle of weld tip, and speed per minute
have been reached. The pressure on weld tip, though important to control
initial fit and fusing of v-weld rod to v-groove, is not as critical as above three
indicators. Careful observance of all these indicators of successful welding
will ensure a weld with proper penetration and full fusion inside weld zone
and through the full ¼” thickness of the sheet is performed each time.
12. Heat-weld.
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(f) When changing weld direction and overlapping welds, cut a small “V” in the
trimmed rod and start welding from the opposite direction until you weld over
the “V” for 2-3” and then lift the rod and heat gun away.
(g) Trim the excess rod while it is still warm – Image 13.
(i) Trim rod using a standard quarter moon knife.
(ii) The rod should be trimmed in one pass, making sure not to remove the
flooring surface along with trimming the rod.
(iii) The color of the weld rod will lighten after excess has been trimmed.
(iv) Hold the heat gun 2-3” away from surface and apply heat until color
changes to match sheet color. Over-searing will result in a gloss finish on
seam.
(3) Cove Cap/Z-Bar. PROTECT-ALL cove cap, aluminum, or stainless steel is
required at the top of the PROTECT-ALL cove base. Both cove caps are
designed to be used when the base off-sets the wall by ¼” (applied over wall tile
or FRP), or prior to the wall tile or FRP being installed.
(a) Prior to applying the cove cap, first seal the top of the cove base with
manufacturer’s specified sealant (Eclectic 6100). For both cove caps, the
down leg (applied over the base) of an outside corner must be continuous
wrap.
(b) Finish the cove cap by applying a small amount of adhesive to the finished
inside and outside corners.
(c) Aluminum Cove Cap (½” x ½” (45°) x 1”) is designed to be applied either
before the wall tile or FRP and base, or after the cove base is attached.
(i) The 1” flange faces down over the base unless the cap is being applied
ahead of the wall tile or FRP, in which case the 1” flange faces up. In this
circumstance, the cap should be secured to the wall using double sided
cove base tape and the manufacturer specified sealant. Otherwise, cove
cap height must be coordinated with the 6” PROTECT-ALL cove base.
(ii) The ½” flange (facing up) that attaches to the wall must have ¼” bead of
the manufacturer’s sealant applied to the back prior to securing to the wall
– Image 14.
13. Skive while V-rod is warm. 13
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(iii) The cove cap should be mechanically-fastened to the wall every 8” – 12”
using the appropriate type and size of screw for the wall type – Image 15.
The screws should penetrate into the wall at least 1”.
(4) Stainless Steel Corner Guards. In high traffic areas, install 4” corner guards on
outside to prevent the corners from being impacted and possibly split open.
(a) Use stainless steel screws to secure and apply Eclectic 6100 to the backside
of the guard.
(b) Door jams, fixed objects, and floor penetrations, such as plumbing, electrical,
and condensation lines, must be sealed by applying Eclectic 6100. Pre-clean
the area using denatured alcohol on a clean white rag to remove any dirt or
oils prior to applying the Eclectic 6100.
5) PROTECT-ALL Adhesives
a) Oscoda Plastics specified #127 and #139 adhesives are low VOC, solvent-free and non-
flammable. They are specifically formulated for use with PROTECT-ALL flooring. They
can be used for both porous and non-porous substrates that are below-, on-, and above-
grade. They are available in 1 gallon units only. Both adhesives have a one year shelf
life and are freeze/thaw stable for up to three cycles.
b) The adhesives are packaged in separate containers marked Part A and Part B. Empty
the complete contents of Part B into Part A. Mix using a rotary motion while at the same
time, lifting from the bottom until the entire contents has been mixed thoroughly and the
color is uniform (no streaking).
c) Immediately pour the mixed contents onto the substrate and spread with a ⅛” v-notch
trowel.
14. Seal back of cove cap
(aluminum or vinyl) with E6100
before securing to wall.
14
15. Pre-drill using ⅛” drill bit. Use
screws and anchors
appropriate for wall type.
15
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d) When applying, the trowel must be held at a 90° angle to the floor for proper adhesive
application and coverage.
e) PROTECT-ALL must be laid into the adhesive immediately.
f) Using a 100 lbs. roller, roll the floor within the first 15 minutes after the adhesive has
been spread, and repeat one hour later. Roll starting in the middle of the sheet, working
out toward the seams.
g) Installation should be free of pedestrian traffic for at least 24 hours. Wheeled carts
should not be allowed for seven to eight days.
h) Never heat-weld seams until the adhesives have cured. See chart below.
i) Clean up using a cloth rag dampened with warm water while adhesive is still wet. Cured
adhesive cannot be removed.
¼” Thick Material
Trowel Notch Size: ⅛” v-notch trowel
Coverage Rate: 70-80 Sq. Ft.
Working Time* Heat Weld Full Traffic
PA #127 30 Minutes 12 Hours 8 Days
PA #139 15 Minutes 6 Hours 8 Days
*Temperatures above 80° will cause the working time to decrease.
6) Maintenance and Care
a) Heavy grease and high traffic areas. Cleaning procedures for PROTECT-ALL Matte
surface (non-gloss) only. NOTE: No matter the flooring type, in high grease and
high traffic areas, you cannot “mop” a floor clean. Mop heads can only soak up so
much grease and oil before they become useless (2-3 cleaning cycles). After that
timeframe, mops only redistribute the same bacteria-filled grease and oil.
Therefore, we recommend that you switch to deck brushes and squeegees to
remove the soiled solution. Only use clean deck brushes to apply the
degreaser/cleaner. NEVER use solvent-based products such as oven cleaner,
acetone, lacquer thinner, paint thinner, THF, MEK, etc. to clean PROTECT-ALL
products.
i) Tools and Materials Needed
(1) Recommended cleaning products: any degreasing type dish soap such as
Dawn® or call Oscoda Plastics for details.
(2) Nylon deck brush (optional weighted brush)
(3) Hose attached to hot water source
(4) Large squeegee with flexible vinyl or rubber blade
(5) Safety glasses
(6) Protective gloves
(7) Wet floor signs
ii) Optional
(1) Circular power floor scrubber with blue or green cleaning pads
(2) Wet vacuum (if floor drains do not exist)
(3) Power pressure washer (exterior only)
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iii) Cleaning Frequency. The following cleaning procedure should take place daily for
heavy grease areas and weekly for high traffic (non-greasy) areas.
iv) Cleaning Procedure
(1) Broom sweep areas to be cleaned first.
(2) If possible, move equipment away to clean behind hard-to-reach areas.
(3) Place Wet Floor signs in areas that are being cleaned.
(4) Apply cleaning agent.
(5) Firmly deck brush the high grease and high traffic areas first, and then the
remainder of the floor.
(6) Complete with a final clean water rinse (hot water, if available). Remove water
with a squeegee.
(a) If the floor has a significant buildup of grease and oil, use a power scrubber
with a blue or green pad to remove the buildup. If a power scrubber is not
available, then steps 1-6 will have to be repeated until all grease, oils, animal
fats, dirt, and stains have been removed.
(b) If using a pressure washer, do not exceed 180 psi and 200°F.
(c) If using a circular floor scrubber, use only the blue or green cleaning pads
and ALWAYS keep the floor wet while scrubbing. NEVER DRY SCRUB
USING POWER SCRUBBERS.
b) Cleaning PROTECT-ALL Gloss products. NOTE: PROTECT-ALL Gloss products
have a factory-applied UV-cured urethane coating. PROTECT-ALL gloss is designed
for “dry areas” only and should never be applied in areas that would expect to have
moisture or liquids on the floor on a regular basis. PROTECT-ALL gloss products do not
require any special buffing, waxing, or cleaning. Light broom sweeping, dusting, dry or
damp mopping are all that is needed. NEVER use solvent-based products such as
oven cleaner, acetone, lacquer thinner, paint thinner, THF, MEK, etc., to clean
PROTECT-ALL products.
i) Tools and Materials Needed
(1) Clean cotton mop
(2) Mop bucket with ringer
(3) Large floor duster or soft bristle broom
(4) Wet floor signs, if damp mopping
ii) Cleaning Frequency. Clean PROTECT-ALL gloss flooring at least once weekly to
maintain its natural luster.
iii) Cleaning Procedure
(1) Use a large floor duster, soft bristle broom or dry mop to clean the floor initially. If
there are dried spills, stains, or black heal marks go to step 2.
(2) Place wet floor signs in areas to be cleaned. Apply a small amount of the
cleaning agent to any spill, stain, or black scuff mark first. Continue using a damp
mop and bucket to clean the remaining floor. The damp mop must be rung out
thoroughly, leaving a minimal amount of liquid on the floor.
(3) Stubborn black scuff marks can be removed by hand using a clean soft rag and a
small amount of cleaning agent.
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(4) The PROTECT-ALL gloss finish is expected to have a 5-10 year wear layer
under normal foot traffic conditions and recommended care.
This installation manual supersedes ALL previous publications.
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