INSTALLATION, SUBFLOOR AND UNDERLAYMENT

2221 Justin Rd
Ste 119-269
Flower Mound
TX 75028
Tel: 855-443-8833
Fax: 214-471-1010
INSTALLATION, SUBFLOOR AND
UNDERLAYMENT REQUIREMENTS
TUFFGUARD Use & Removal:
Tuffguard is a temporary protective barrier designed to protect the surface of the material from foot traffic & scuffing
from fine abrasives during installation. It is extremely important that Tuffguard be removed within 30 days to
prevent possibility of any residue remaining from the adhesive used to hold TuffGuard. If not removed within 30
days, Tuffplank is not responsible for labor or material to remove any possible residue left on the surface of the vinyl
plank. Tuffguard will NOT prevent damage from abuse. Sharp and/or heavy objects will tear and allow damage to
TuffGuard and wear surface under it.
Tuffguard vinyl planks come equipped with easy-grip tabs for removal of the Tuffguard protective barrier on one end
of each piece. The flooring installer (sub-contractor) is responsible for cutting planks at the proper end so as not to
cut that tab off. The planks must be installed with the Tuffguard Easy Grip TAB up and not squeezed between the
joints . Tuffplank will not be responsible for additional labor to remove Tuffguard or any labor or material needed to
repair the plank if damage occurs to the vinyl tile trying to remove the Tuffguard protective barrier due to the Easy
Grip Tab not being accessible.
Understanding your Installation Setting
Prepare for Installation Day
Review your installation site both inside AND outside to find potential trouble spots BEFORE you start installing
TUFFPLANK Flooring.
Where possible, check around the structure you intend to install TUFFPLANK flooring in for sources of, or
* accummulation of, water near the foundation. ANY water that may be accummulating by the building, regardless
of the proximity to your installation site inside, could create excess moisture, pH or RH in your substrate.
Know your Substrate! Is your substrate a concrete foundation, wood or other product? Not all substrates are
* approved for use under TUFFPLANK flooring. Review the approved substrate list to be sure TUFFPLANK can be
installed in your building. Even concrete has specifications that must be met in order for your flooring to
successfully install.
ALL sub-strates must be tested for moisture, pH and RH (Relative Humidity) before installing
* TUFFPLANK flooring. Any floor installed on an untested substrate, or substrate with unacceptable test
results as defined by TUFFPLANK, will void their TUFFPLANK warranty.
New concrete slabs (foundations) must cure for a minimum of 90 days AND must meet all moisture, pH and RH
* requirements prior to installation of TUFFPLANK flooring. Review the acceptable ranges for these items in the
Moisture, pH and RH section of this manual.
* Verify the substrate is level. TUFFPLANK requires sub-floors to be level within 1/8" in a ten foot radius.
Be sure that Radiant Heat sub-floors are properly cast 1/2" below the surface of the concrete slab. This ensures safe
* use of the radiant heat sub-flooring and provides the proper distance between the adhesive and TUFFPLANK
flooring for proper installation under TUFFPLANK's warranty.
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Room & Flooring Preparation
TUFFPLANK Flooring Preparation
Do not expose TUFFPLANK to extreme conditions or temperatures. Once flooring has been delivered, verify color and
lot numbers. Store boxes flat so that the planks are sitting as they would on the floor after installation, not on their
edges. The boxes must be in a warm, dry area, preferably the room they will be installed in.
Building and Sub-Floor Temperature
2221 Justin Rd
Ste 119-269
Flower Mound
TX 75028
Tel: 855-443-8833
Fax: 214-471-1010
Preparation for Installation begins weeks, sometimes months before the actual installation begins. For instance, new
concrete flooring must cure for a minimum of 90 days before beginning these activities.
3 Weeks Prior to Installation Where applicable, radiant heat sub-floors should be actively used to drive out moisture and to assist in the calibration
of the flooring temperature to 70° and 80° Fahrenheit beginning.
1 Week Prior to Installation Turn on the building's heating and air-conditioning system one week prior to installation and set at a consistent 70°
and 80° Fahrenheit. Be sure that your heating & air-conditioning units can operate properly throughout the
installation event, including potential extra drying/curing times as needed.
3 days prior to installation Turn off radiant heat sub-floors IF moisture, PH Testing, and other preparatory steps identified in this guide have
successful results for installation.
48 hours before scheduled installation
- Acclimate all materials to jobsite conditions
o between 70° and 80° Fahrenheit for proper installation.
- Set Room & Sub-Floor Temperature to
During Installation keep room & sub-floor temperature between 70° and 80° Fahrenheit.
After installation - maintain room & sub-floor temperatures between 70° and 80° Fahrenheit.
Post-installation - radiant heat sub-floors must remain off for a minimum of 6 days to allow adhesive to fully cure.
Failure to follow these instructions may result in an installation failure (i.e. flooring may expand or contract resulting
in gapping).
NOTE: Never operate the radiant heat flooring above 85°F. Separate ALL radiant heat components by a minimum of
½” (or more if Radiant Heat Component Manufacturer states different requirements) from adhesive and tile for safe,
proper operation post-flooring installation.
Porosity:
A non-porous substrate is one which does not absorb water. If you are not sure whether a floor is porous or nonporous, sprinkle some water on the floor over several different areas. If the water beads up, then it’s a non-porous
floor. If it soaks in, it’s a porous floor. Use a small amount of water for the test, and allow floor to completely dry before
continuing. If a bare concrete floor is not porous, a sealer or curing compound may have been used. Such treatments
should be removed before installing a new floor or underlayment, and the floor retested for porosity at that time.
Note: Adding latex to levelers normally cause floors to become NON-POROUS.
Moisture, Relative Humidity & PH Levels:
TUFFPLANK requires all concrete sub-floors (new and old) be tested for moisture, pH and Relative Humidity.
Moisture testing is currently done using the Calcium Chloride Test ASTM F1869. pH testing is done using the ASTM
F710 model and RH (Relative Humidity) testing is done using the ASTM F2170.
Concrete sub-floors must have moisture barriers installed under the slab and be determined, through testing, to be
dry and not subject to water absorption.
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Wood sub-floors may also be affected by moisture. Most often, this is evident through warping or damaged wood
although it may not always be visible. Moisture tests must be done on ALL flooring types, regardless of the material
they are made of.
Do NOT install TUFFPLANK vinyl where surface or sub-floor moisture is evident as moisture content above
acceptable range will cause installation failure. New concrete slabs must cure for a minimum of 90 days prior to any
installation of flooring. Existing concrete slabs should be closely evaluated for moisture problems. The Installer is
responsible for completing the moisture test prior to installation. Failure to test may result in an unknown moisture
content that will affect your installation adversely! MOISTURE GUIDELINES FOR THE FLOOR COVERING INDUSTRY are
available from the World Floor Covering Association, at 1-800-624-6880.
2221 Justin Rd
Ste 119-269
Flower Mound
TX 75028
Tel: 855-443-8833
Fax: 214-471-1010
Moisture Tests should have no more than 8lbs per 1000 sf in 24 hours MVER or be greater than 14%.
PH tests verify alkalinity levels and should have results between 7 and 9.
RH test results should not exceed 85% or 8lbs per 1000 sf in 24 hours MVER.
Results outside these ranges require further preparatory work before TUFFPLANK installation can begin. In the case of
a pH level above a 9, TUFFPLANK flooring cannot be installed until the pH levels are brought down.
NOTE: Electronic meter testing is not considered a replacement for a Calcium Chloride Test.
Moisture has a direct effect on the cure, set and bond of adhesives. On well-cured adhesives, the presence of pH
values outside the proper range has proven to be the most significant factor in adhesive failures. Moisture is present
in all instances where pH levels are above the acceptable range. Thus, reducing moisture may assist in bringing pH
levels back into range for installation of your TUFFPLANK flooring.
Understanding your installation area
Approved Subfloors
1.
Concrete: Only structurally sound concrete of proper density (90 lbs/cubic foot) and compressive density
(3,500 psi) should be used as a sub-floor for TUFFPLANK flooring. Concrete must be clean, dry, smooth, and
free of paint varnish, adhesive, oil, grease, solvents or other extraneous material (i.e. curing and parting
compounds, sealers and surface hardeners) that will inhibit bonding. Never assume a concrete floor is
porous! Always be sure to remove old glued down carpet and scrape the old adhesive off the concrete.
Frequently though, the old adhesive has sealed the floor, therefore, a porosity test, using water, should
be done. Porous subfloors may take a different adhesive than non-porous subfloors so review your
adhesive container for instructions.
NOTE: If oil, grease, or other contaminants have deeply penetrated the concrete, and cannot be
thoroughly removed, TUFFPLANK cannot be installed. If latex liquid has been used to seal off old
cutback adhesives, the concrete has become non-porous.
2.
Lightweight concretes: Only concrete with a density of 90lbs per cubic foot and a compressive strength
of 3,500 psi are approved as a sub-floor under TUFFPLANK products. Concretes with density under this
value are used most often as thermal or sound insulation for roofs, floors and walls and are inherently weak.
Gypsum and other forms of light concrete may be used when they meet these requirements but when
installing over them, always apply an Acrylic based Primer-Sealer coat prior to applying adhesive.
3.
Wood sub-floors: TUFFPLANK is approved for use only on standard double layer construction wood floors
of proper wood types (see non-approved substrates for further details). A wood sub-floor must have a
finished thickness of at least 1” and at least 18” of well ventilated air space underneath. Crawl spaces under
these sub-floors must be insulated and have a vapor barrier for moisture elimination. Do not install vinyl
flooring over a sleeper type sub-floor or over plywood when it has been installed directly on a concrete slab.
Approved Underlayments:
1.
PLYWOOD: Only American Plywood Association (APA) underlayment grade plywood with a minimum ¼”
thickness may be used. Provide expansion spacing between plywood butt joints of 1/32” – 1/16”.
Stagger cross-joints 4’ on an 8’ panel (minimum 16”), lightly butt the panels together, and set fasteners flush
or slightly below the surface level of the underlayment. Use Portland cement-type floor patch to fill all
uneven areas such as underlayment seams, nail holes and indentations. Allow floor patch to dry following
manufacturer's instructions. Sand patch to smooth an uneven areas then remove any dust/dirt from the
area. Apply adhesive (all dust must be COMPLETELY removed to ensure a strong adhesive bond). In some
cases a manufacturer-certified Poplar, Birch or Spruce plywood underlayment product with a fully sanded
face can be used when they are built using exterior glue.
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2. LAUAN PLYWOOD: Only Type 1 (exterior grade), minimum Grade BB, preferably grade CC, may be used as
an underlayment to TUFFPLANK Flooring. Lesser grades or types of Lauan plywood are approved and
TUFFPLANK warranties will not apply if installations are done over un-approved products. The types and
grades of lauan plywood that are not approved may present severe problems including discoloration,
indentation, loss of bond and delaminating when used as an underlayment.
NOTE: Lauan is a very porous product as are many other non-approved sub-floor products. These products
may reduce the flash and working time of adhesives. It is best to use an acrylic-based primer/sealer coat to
seal these products prior to applying adhesive. Any claims for flooring issues to TUFFPLANK on lauan
underlayment installations must be accompanied by the manufacturer's certification of lauan grade.
2221 Justin Rd
Ste 119-269
Flower Mound
TX 75028
Tel: 855-443-8833
Fax: 214-471-1010
Underlayments are frequently used to create a barrier between old adhesives or flooring and the new installation. If
the underlayment product you are using is not explicitly approved in the installation guide , contact TUFFPLANK
Technical Support to confirm that the product you intend to use will not void your TUFFPLANK warranty. There are
special requirements for this group of products that are designed to provide your floor with a long life. Use of nonapproved underlayments and substrates will adversely affect adhesion, installation success/failure, and the life of
your flooring.
Allow at least 24 hours for underlayment drying before installing TUFFPLANK flooring. I f s elf-leveling u nderlayments
are used they must fully cure before installing TUFFPLANK floor tiles. Test self-leveling compound for moisture
before installing.
The installer is fully responsible for moisture, leveler-related and installation problems.
Never install over more than one layer of existing flooring.
Non-approved Substrates
- Waferboard
- Oriented Strand Board (OSB)
- Hardboard
- Strip Wood Floors
- Tile backer boards containing cement
- Chipboard
- Masonite
- Particleboard
- Glass Mesh Tile Boards
- Asphalt, Rubber or Self-Stick Tile
- Plywood with knots, preservatives, or other treatments including fire-retardant product
Testing your Sub-Floor
When in doubt, or unable to be completely certain that your sub-floor will accept the adhesive and TUFFPLANK
Flooring, do a small section Bond Test. This test can also be used to help verify porosity of your sub-floor for
proper adhesive use.
Bond Test Method: Use the flooring and adhesive suitable for the subfloor as you know it. Install a 2’x2’ section
following the recommended installation procedures. Sections next to walls, columns, or other light traffic areas
are best suited for this test. Tape the perimeter of the test planks/area with duct tape to prevent edge drying of
the adhesive. At the end of 48 hours the adhesive should be dry and the flooring should be difficult to remove.
Note: the adhesive is dry at this point, but not cured. Full cure and maximum bond does not occur for 6-8 days.
SUBFLOOR PREPARATION
The substrates where TUFFPLANK will be installed must be free of dust, dirt, weak concrete, grease, wax, oil, sealers,
paints, curing compounds, old adhesives, or any other potential contaminant. Sub-flooring surfaces should be
leveled to within 1/8 inch in ten feet including all constructions seams, expansion joints, and holes.
Old asphaltic “cut-back” adhesives can destroy new adhesive and stain TUFFPLANK vinyl, which is not
covered under the TUFFPLANK Warranty.
Properly prepare substrate by grinding or sanding. Concrete floors will react best to long-term use of TUFFPLANK
flooring when ground to level, rather than use of fillers or levelers.
Be sure to remove ALL grinding dust to allow for a strong adhesive bond. Surface irregularities will telegraph
through the tile causing uneven floor, reduced flooring life & possibly voiding your TUFFPLANK Warranty.
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Removing Old Adhesives:
WARNING: Old adhesives may contain Asbestos fibers that cannot be seen. Therefore, power removal devices,
that create dust, should not be used to clear floors of old adhesive. Do not use solvent-based adhesive removers to
prepare the substrate. Use of d-limonene (citrus-based) cleaners/removers are acceptable but must be thoroughly
rinsed from the sub-floor.
All old adhesive must be completely removed, encapsulated or covered with plywood underlayment. Be sure
to remove adhesive in dips, joints, etc.
2221 Justin Rd
Ste 119-269
Flower Mound
TX 75028
Tel: 855-443-8833
Fax: 214-471-1010
In the event that the old adhesive cannot be completely removed consider covering them with plywood. Should this
not be possible it is acceptable to use Portland Cement-Based Leveling or Patching Compound. Use of self-leveling
underlayments often have a very high moisture content. In the event that these are used, they must fully cure before
installation of flooring can occur. NOTE: Curing times may be as long as 10 days or more for self-leveling compounds
Approved Adhesives
Only Mapei Ultrabond ECO 350 is approved for use with TUFFPlank Vinyl. All instructions and requirements from
Mapei must be followed, including but not limited to approved working times in order to be covered by TUFFPlank's
warranty.
All flooring must be rolled by a 100 lb roller after installation in order to help adhere flooring to adhesive
properly within the required timeframe as defined by Mapei. In hard to reach areas, use a hand roller. Failure to do so
can result in lack of bond and/or excessive thermal expansion, or contraction.
Patching & Leveling:
Sub-flooring surfaces should be leveled to within 1/8 inch in ten feet including all constructions seams, expansion
joints, and holes. The use of levelers on non-porous sub-floors will not create a porous sub-floor.
Only Portland Cement-Based Leveling or Patching Compounds are approved for use with TUFFPLANK products!
Follow the manufacturer’s instructions for proper application of patching or leveling compounds. Sand
underlayments, once cured, become smooth and may not be useful for proper adherance to TUFFPLANK products.
The installer is responsible for cure times, moisture content, adhesive bonding and the structural integrity of
any leveling or patch compound used.
Use of latex in a leveler typically makes the floor NON-POROUS and will require a different type of adhesive for proper
installation of TUFFPLANK flooring. Always do a moisture test and confirm proper test results before moving on to
installation of flooring regardless of the leveler or patching compound used. Underlayments must dry at least 24
hours (or until fully cured) before installing TUFFPLANK unless self-leveling compounds are used.
Embossing Levelers:
Embossing levelers are not recommended for use in a TUFFPLANK installation. These are appropriate for sheet goods
with textures that may telegraph through TUFFPLANK flooring and be visible on the surface.
Sealers:
There are no TUFFPLANK-approved concrete or floor sealers. IF MOISTURE IS PRESENT, DO NOT INSTALL FLOOR.
Sealers may be helpful in alkaline environments or as a barrier between old and new adhesives. As a barrier they help
deaden old adhesive tack, prevent plasticizer migration and seal over dust or old cutback adhesives. Most latex- and
acrylic-based sealers are compatible with TUFFPLANK adhesives and should be applied following the manufacturer's
instructions. Evenly distributed application of the sealer, with NO Gaps, across the entire surface of the floor is
important for proper drying. Sealer must be completely dry before applying adhesive.
Existing Resilient Floors:
If your installation area has an existing resilient floor, TUFFPLANK recommends removing it before installing
TUFFPLANK products.
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All existing tile, resilient floor or new sheet vinyl must be stripped using TUFFPLANK approved stripper to remove wax
or other contamination and rinsed with clear water and allowed to dry. Lightly abrade all high-gloss or very smooth
floors. This roughs up the surface allowing proper adhesive bonding for the new application of flooring. In rare cases,,
an existing resilient tile or sheet vinyl floors may be in good condition, thoroughly bonded to the structural floor and
may accept an installation
at of TUFFPLANK without full removal.
NOTE: Never install TUFFPLANK over any cushioned flooring/construction or over more than one layer of existing
resilient flooring.
Quarry Tile, Terrazzo, Ceramic Tile:
2221 Justin Rd
Ste 119-269
Flower Mound
TX 75028
Tel: 855-443-8833
Fax: 214-471-1010
Commercial degreasing and dewaxing solutions are appropriate for preparing existing tile for TUFFPLANK
installation. Grind any highly polished or irregular surfaces. Where grinding is not creating level flooring, fill in any
low spots, holes, chips and seams to remove uneven areas that could impact your TUFFPLANK installation. Test for
porosity and use the appropriate adhesive application method. Bond tests are required on these types of installation.
TUFFPLANK Installation
All prior preparation activities are complete and test results are within proper ranges! You are now ready to install
your TUFFPLANK flooring.
First, find the center point of the room. Use of a carpenter's square or chalk-lines may be helpful! Be sure you have a
90° angle at the center point as your entire installation will be based upon this mark. Divide the room into 4 equal
parts by marking a second chalk-line. (Diagram A)
Diagram A
Diagram B
Diagram C
Measure the distance between the center of the room to the wall, parallel to the direction of the first plank as seen in
Diagram B. (example = 10 ft) Divide this measurement by the width of the plank. (example 4"). When laying planks,
be sure to leave a small gap around the perimeter of the room for expansion and contraction.
NOTE: If the equation does not allow for at least 1/2 the width of the plank as a border, adjust the center point. The
intention here is to give a larger border along the wall, reducing the need to cut small sections of planks length-wise to
place along the wall.
Install the planks beginning at the intersection of the chalk lines, laying each plank flush against the chalk line in the
first row and tightly against the adjoining plank. Each plank should be well-seated into the adhesive, making sure that
the edges of the planks are well-connected as well. Use planks from several different cartons to create a more blended
floor with minor shade variations. If the TUFFPLANK Tile or Plank has directional arrows follow accordingly. If there are
no directional arrows lay tile and planks keeping the embossing of the product flowing in the same direction.
Continue laying planks row by row, using a pyramid form as shown in Diagram C until no further full-length planks can
be seated.
Completing the Border: Measure the distance from the last full plank in the row to the wall. (example = 20") Cut the
next plank to this measurement being careful to cut the PROPER END of the plank especially when installing
TUFFGuard! Place the cut edge of this plank against the wall making sure to seat this into the adhesive properly. Don't
forget to leave a small gap for expansion & contraction of the flooring between the end of the plank and the wall.
Irregular Objects: When laying TUFFPLANK floor around non-squared objects (i.e. pipes, etc), take a plank and draw
the shape of the object on it, then trace-cut the plank along those lines.
NOTE: TUFFPLANK warranties its Tile to be free of defects. The condition of a subfloor, which causes adhesion
problems due to not recommended, improper, incorrectly prepared sealers, embossing leavers, patches,
concrete, etc, becomes the sole responsibility of the installer and/or manufacturer of the particular subflooring product. For further information, please see the TUFFPLANK Warranty.
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