Finished Flooring

By now it should be clear that attention to the framing and subfloor construction details can mean the difference between quality construction and floors that are compromised and prone to squeaks and other defects. Only after these structural components are properly addressed does it then make sense to look at the finish flooring. As noted earlier, most of the issues that show up in the finish flooring after a building is occupied is usually the result of problems with the subfloor system. This can be true if the subfloor is uneven or unstable to begin with, and can also become true if the materials are damaged during construction or if the bond between the subfloor panels and the framing members isn’t complete. Hence, it is critical to address all of the issues we have talked about thus far before considering any expenditure on the finish flooring to be sure that the finish flooring can also be installed properly to mitigate risks of squeaks.

Finished flooring in the form of carpeting, wood flooring, or tile can all be accommodated successfully and securely with high-performance subfloor panels.

All of that said, there are some things to consider about the finish flooring itself to be sure that the project is completed properly and squeaks or other defects are avoided. The first is to be sure that the finish flooring and the subfloor system are designed and installed to work together. If they are nailed or secured together and one deflects or bends differently than the other, differential movement can occur between them as evidenced by telltale floor squeaks. In the case of wood flooring, that means proper nailing and proper installation following established guidelines and recommendations. For laminated or engineered wood products, the manufacturer’s recommendations and installation directions need to be adhered to. Most natural wood-plank flooring will have cleats or staples holding and securing the flooring to the subfloor. If the subfloor deflects too much or does not have the ability to hold on to the cleats or staples under foot traffic, then squeaks and pops can occur. In order to avoid this source of floor noise, it is important that the subfloor be both stiff and high in fastener holding power. For ceramic or porcelain tile flooring, underlayments can be adhered, fastened, or, in some cases, float on top of the subfloor. For the fastened systems, it is important for the subfloor be able to grab the fastener and not let go. However, no matter what underlayment is used, it is always important that the subfloor be stiff and not have excessive deflection. When a subfloor sags too much, cracks can occur.

It is prudent to keep in mind the finish flooring when selecting subfloor panels since some are better suited to success than others for different flooring types. OSB is fine for carpets but can be prone to nail pops if a strong, high-performance engineered wood panel is not specified. Further, traditional OSB may not work as well for some hardwood flooring if it has become uneven from swelling during exposure during construction. Plywood may provide adequate strength, but it still requires diligence to avoid problems with edges and seams if delamination occurs from moisture during construction. High-performance engineered wood panels have been used successfully on all finish flooring types, which is particularly useful if the final selections are uncertain or subject to change.

Conclusion

Architects, builders, contractors, and remodelers who have experienced the pain of job delays, callbacks, or professional liability for squeaky subfloors can now work to avoid those problems. The combination of appropriately selected floor framing and high-performance engineered wood subfloor panels held together with deformed fasteners and polyurethane spray-foam subfloor adhesive can meet high-quality expectations for a solid, quiet flooring base. Further, the subfloor system can help reduce squeaks, bounce, or uneven finished flooring results by being designed with materials providing powerful moisture resistance, strength, and stiffness characteristics that help subfloor panels stay flat with no sanding required, even after exposure to harsh job-site conditions. In the end, the result is a quality project that will hold up over time and provide the intended satisfaction to the owners and users.

MULTIFAMILY CASE STUDY

High-Performance Engineered Wood Subflooring Stands the Test of Time in Multifamily Construction Projects

Kevin Rogerson of Lindsey Construction Co. Inc. has been involved with building multifamily residential units in northwest Arkansas and seven surrounding states for more than two decades. When asked to name the number-one construction issue in building apartment homes, he doesn’t hesitate to answer. “Sound,” he says. “Think about how many people walk on flooring in multifamily units each day, then multiply that over the lifespan of a unit. Residents want quiet, stiff floors, and the construction materials we choose for our projects offer that assurance.” Floor squeaks are a definite problem to avoid in this case.

Because of Lindsey Construction’s focus on building strong, resilient homes, the company uses high-performance wood engineered subflooring that performs differently from plywood and traditional OSB, for its construction projects. Rogerson, who helps oversee the construction of 1,500 to 1,800 multifamily units annually, says, “We’ve used the product for over 15 years and know firsthand it is designed to reduce the possibility of floor squeaks, which is critical in multifamily residential.” He also acknowledges that the high-performance engineered wood subfloor not only helps resist moisture during construction, but also during the life of their buildings in the event water seeps down below the finish floor for any reason.

“There’s no question that multifamily units require durability,” he says. “The high-performance engineered wood subflooring we use is a strong, sturdy product that helps us provide homes with a solid feeling. This translates into a quieter living area.” In addition, Rogerson adds, because the mindset at Lindsey Construction is to manage the lifestyle expectations of its future residents, the company only uses quality products that stand the test of time. “We’ve never had any problems with it and have no intention of trying anything else since these panels perform as intended in our projects.”

SINGLE-FAMILY CASE STUDY

Some Subfloors Have Held Up While Others Have Not

Brian Hall of Classica Homes in Charlotte, North Carolina, has been using high-performance engineered wood subfloor product ever since Classica Homes was started in 2010, and for an additional 10 years before that. Having a high-quality subfloor to install expensive hardwood floors over is critical, according to Hall. “If that part of the job isn’t done correctly, it doesn’t matter how you cover it up, you’re going to have problems,” he says.

While there were several reasons to give high-performance engineered wood subfloor panels a try over the previous product the company was using, the switch ultimately came down to providing quality for their customers. Hall remembers one particular winter where torrential downpours invaded Charlotte, North Carolina, for weeks on end. At that time, the company was using a high-performance engineered wood subfloor product on some homes and a value-priced panel product on others. After the storms passed, so too did its time using that value-priced panel. “The high-performance engineered wood panels held up unbelievably, while we had all kinds of issues with the other panel, such as nail retention problems, hardwood issues, moisture problems, and floor squeaks.”

The high-performance subflooring product that it now uses has maintained an International Code Council Evaluation Service (ICC-ES) report to elevate it from other subfloor products. The result? The report documents that this specific high-performance subflooring has endured a battery of testing protocols that measure and ensure greater and consistent levels of panel strength, stiffness, and fastener holding power when compared to other panels. Specifically, it cites 62 percent better bending strength than PS-2 quality OSB or plywood panels of the same dimension; 28 percent better bending stiffness than PS-2 quality OSB2; 16 percent better bending stiffness than PS-2 quality plywood; and 10 percent better fastener holding power than both PS-2 quality OSB and plywood.³

Hall says his hardwood flooring installer has been thrilled ever since making the permanent switch to high-performance subfloor panels. The main reasons he prefers it over alternatives is because the high-performance panels stay flat and make it is easier to apply and install the hardwood. Further, the integrity of the subfloor and the proper gaps assure that the hardwood seams will not buckle. “Houses that use the high-performance subflooring have held up, and those that use a value-priced panel product did not,” says Hall. “The high-performance panels are just a far superior product for nail retention and definitely a more substantial product. When fastened to the structural members, it certainly strengthens the overall floor.” Hall isn’t bashful about telling other builders that they should be offering the same quality floor system he is to their customers. “If you’re not using this particular high-performance engineered wood subflooring, you are risking your business. It is too good of a product to not use in your home, and it’s a no brainer that will save you from the backend headaches.”

Foot Notes

¹ Clark, Bob. “Top 10 Framing Errors and How to Avoid Them.” Professional Builder. 18 February 2012. Web. September 2016. http://www.probuilder.com/top-10-framing-errors-and-how-prevent-them.

² Henkenius, Merle. “Fixing a Squeaky Floor.” This Old House. Web. September 2016. https://www.thisoldhouse.com/how-to/fixing-squeaky-floor.

³ See ESR-1785, an Evaluation Service Report by the International Code Council’s Evaluation Services, for the only structural panel with documented design values for strength, stiffness, and fastener holding power above code standards (PS-2).

⁴ When tested in accordance to ASTM D3498 standards, one spray-foam, gun-applied subfloor adhesive shows a bond that is two to five times stronger than the code minimum under various conditions.

⁵ Based on one spray-foam subfloor adhesive manufacturer’s testing: One can of the cited subfloor spray-foam subfloor adhesive yields approximately 400 linear feet of at a ¹/₂-inch diameter bead. When compared to a 28-ounce caulk cartridge of typical subfloor adhesive, applied at a ³/₈-inch bead per the manufacturer’s instructions, the spray foam yields approximately eight times the coverage than that of the conventional adhesive. That means it would take eight cartridges of conventional adhesive to cover the same construction area as one container of this spray-foam adhesive.

⁶ See the International Residential Code (IRC), published by the International Code Council, Inc. (ICC).

Peter J. Arsenault, FAIA, NCARB, LEED AP, is a practicing architect, green building consultant, continuing education presenter, and prolific author engaged nationwide in advancing building performance through better design. www.linkedin.com/in/pjaarch

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