Installation Instructions

INSTALLATION INSTRUCTIONS – MILLIKEN CARPET
TUFTED BROADLOOM – PATTERNED, NON-PATTERNED AND ATTACHED CUSHION
• Milliken strongly recommends the use of a Milliken Certified Installation Contractor to install all broadloom products. Installation contractors certified by the
Floor Covering Installation Board (FCIB) as well as firms that can document the employment of installers certified by the International Certified Floor-Covering
Installers Association (CFI) at the R2,C2 or master level are also recognized as sources of good quality installation labor.
• Except where exceeded or modified by this instruction, Milliken recognizes CRI documents 104 (Commercial) and 105 (Residential) as the standard for the
installation of its products.
NOTICE – Dealer and/or installer must inspect carpet prior to installation. Milliken cannot be responsible for visible defects after carpet
has been cut and installed.
STRETCH –IN (OVER CUSHION) INSTALLATION:
As in all broadloom carpet installations, lay the carpet flat, remove wrinkles and allow the carpet to condition sufficiently at room temperature – which should not be less than 65
degreesF (18ºC). Extra effort will be required to stretch the carpet if installed below 65 degrees F (18ºC). Carpet should be maintained after installation between 65º and 85ºF
(18º to 30ºC). Drastic changes in temperature and humidity can cause wrinkling in installed carpet.
STRETCH THE CARPET
• Stretch synthetic-backed (ActionBac®) carpet more than jute-backed carpet. Don’t worry about overstretching.
• Stretch selvage-to-selvage just as much as end-to-end.
• Stretch at least 1% in both directions. (Length and width).
• A good rule of thumb is to stretch 1½ inches per 12 feet (3.81cm per 3.66m)
• See the seven-step stretching procedure below.
STRETCHING AND HOOKING PROCEDURE:
Below is a 7-step technique for successfully power stretching a room. (See diagram).
1. Using a knee kicker, hook carpet in corner A as indicated by heavy lines and power stretch from A to B at a 15º angle. Hook carpet in corner B.
2. Using a knee kicker, hook wall AB firmly onto the tack strip working from A to B at a slight angle.
3. Power stretch from wall AB into corner D at a 15º angle. Hook carpet in corner D.
4. Using a knee kicker, hook wall AD firmly onto the tack strip.
5. Power stretch from wall AD into corner C at a 15º angle. Hook carpet in corner C. Note: This is a temporary tensioning stretch, which allows stretching into wall DC.
6. Power stretch from wall AB into wall DC working at a 15º angle toward corner C. Stretcher head should be moved no more than 2 head widths between each successive
stretch. Approximately 2 to 3 stretches before reaching corner C, unhook the tensioning stretch taken in step 5 and complete stretching into corner C.
7. Power stretch from wall AD to wall BC working towards corner C at a slight angle.
Caution: Make sure carpet is uniformly stretched at least 1% in both directions. To aid you, we suggest you chalk (white chalk) a line across the carpet close to the wall and
measure the distance this mark travels toward the wall.
Note: Carpet stretched in over existing carpet is not recommended or guaranteed.
In large areas the use of a commercial stretcher is recommended (Roberts 10-222 Senior Stretcher). Large areas should be subdivided into smaller roughly rectangular areas with
each area stretched as described above.
CUSHION RECOMMENDATIONS:
RESIDENTIAL: – Maximum Thickness is 7/16” or 11.2mm (nominal) regardless of type cushion chosen.
• Bonded Polyurethane: Minimum Density - 6.5#/cu.ft.
• Prime and “densified prime” Polyurethane- Minimum Density – 2.8#/cu. ft.
• Needled Synthetic(felt)-Minimum Density 32 oz./sq. yd.(1.1 Kg/sq. meter)
COMMERCIAL:
• Needled Synthetic-Minimum Density – 40 oz./sq. yd. (1.35 Kg/sq. meter
Maximum Thickness – 3/8” (9.5mm)
• Slab Rubber (vulcanized synthetic rubber such as Tred Mor®)
Minimum Density –18#/cu.ft. Maximum Thickness - ¼” (6.4mm)
Note: Improper cushion is a leading cause of re-stretch callbacks, seam failure,
unsatisfactory carpet performance and poor appearance retention.
SEAMING PROCEDURE:
1. All methods of seaming are acceptable, however, the thermoplastic or “hot melt” method gives the strongest seam in the least amount of time and is the
recommended procedure. Wider 6” (15cm) tapes are available where seam peaking is a concern. Always use a premium quality seaming tape
2. The following seaming tapes are recommended:
• Super 3 (Stretch-in only) and K-80 for direct and “double stick” – Orcon Corp – 510 489 8100
• GT-350(Stretch-in only) – Roberts Consolidated Industries (a QEP Company) – 800 423 6545
• Seaming iron should be equipped with a heat shield to prevent damage to backing and face yarns. Seams should be made on a hard flat surface.
All cut edges MUST be sealed. Milliken “Barrier Bond” seam sealer is recommended. Refer to pattern 500576/920/00001 when ordering. This product is packaged in 8 ounce
squeeze bottles with a standard “Yorker” tip. One (1) case is the minimum order. Each 8-ounce bottle will cover 200 linear feet of seam. Thermoplastic chemistry is also an
acceptable method for preparing/sealing seam edges. This can be accomplished using a number of available hot melt guns and applicator tips designed for this purpose.
Gundlach – 618 233 1781 and Orcon (#above) are the most widely available sources for this technology.
CUTTING PROCEDURE:
• For cut pile non-patterned carpet, the preferred method of cutting is to row cut both breadths, however, on tufted carpet the rows are occasionally not straight enough to
allow this. If this is the case carpet should be chalk lined and straight edge cut from the back using a sharp razor knife.
• When cutting from the back, care should be taken to just cut through the backings. Cutting too deeply can damage the face yarns and cause an unsightly seam.
• On non-patterned loop pile fabrics, row cut both breadths if possible. If not, row cut one breadth, overlap and scribe cut the second breadth using a cushion back cutter.
• Remember that seam sealing is mandatory on all carpet.
• On patterned carpet, regardless of construction, cut along complementary patterns. This can be done using a “Cushion Back Cutter” and straight edge from the face or
Gundlach’s # 295 “UniCutter” and “Hang Over Straight Edge” also used from the face.
• An alternate method for patterned carpet is to slit the carpet approximately every 3’ (1m) from the face along complementary pattern points and cut between slits from the
back.
PATTERN MATCH TECHNIQUE:
• Trim both breadths to be seamed along complementary pattern points as directed above.
• For best results and maximum ease of installation, lengthwise pattern repeat, pattern bow, and pattern bias should be measured on all rolls to be installed. These
measurements are made as part of the final inspection process in manufacturing and are available on roll tags and on the packing list that comes with each shipment.
Site measurement of these properties allows the contractor to “fine tune” the sequence of installation. Measure these as follows
1.LENGTHWISE PATTERN REPEAT: (L.P.R.)
a. Divide published length pattern dimension into 144” for 12’ (3.66m) wide material or 162” for 13’6” (4.1m) wide material. This answer will generally be a whole number.
If not, round up to the next higher number. Example: On 13’6” (4.1m) wide material having a 40.5 ” length repeat, 40.5 goes into 162 four (4) times.
b. Measure along both selvages on each roll that number of pattern repeats obtained above (4 in this example). This measurement will typically be slightly larger or smaller
than 144” or 162” (3.66m or 4.1M). In any dye lot, all measurements obtained in this way will vary no more than 2” (5cm).