Software
Houzz Logo Print
newkit1_gw

Installing DuraCeramic?

17 years ago

In remodeling our 12x15 kitchen (our first major remodeling after 25 years in the same house), we decided on Congoleum DuraCeramic tile, mainly due to our need for a resilient floor to go easy on our aging feet and legs. The KD/GC told us upfront that they donÂt do flooring, so our contract specifies only removal of existing flooring. We understood that we would have to hire a flooring contractor to install the DuraCeramic, but did not choose one yet since the KD/GC said that the new floor would be installed last, and there were so many other choices that needed to be made first. The flooring places we did talk to before demo began did not inspire confidence, so we put off selecting the flooring contractor.

Our old sheet vinyl floor had some water damage from a leaking dishwasher, so in getting the old vinyl off, some (but not all) of the of the underlayment came up with it, and the plywood subfloor in that area was spongey. The KD/GC agreed to replace this area of the subfloor before the cabinets are installed. However, it seems to us that perhaps more should be done with the floor (remove/replace the rest of the old underlayment?) before the cabinets go in, to avoid damage to the new cabinets. The rest of the floor has some squeaks, and the underlayment is stapled down, with some protruding staples and adhesive residue. The KD/GC wants to move on, and is not giving us much guidance on this.

Now we are in a panic trying to get flooring advice. The Congoleum installation guide for DuraCeramic recommends high-quality plywood underlayment, such as Halex or other 5-ply arctic birch, or their own roll-up underlayment called "Under-Flor" that will provide a floating floor. Congo specifically does NOT recommend lauan.

We have talked to several flooring places in our area that carry DuraCeramic and that have good recommendations on CheckBook, the local DC/MD/VA online rating service. All are kind of vague as to how much DuraCeramic they have installed. All of them say they use lauan and none have even heard of Under-Flor, so we havenÂt found any that give us confidence that they could do a good install.

It seems like installing DuraCeramic is not rocket science, so we are considering hiring a small contractor/handyman we have used in the past to install new windows and doors and whose work we like, to put in the DuraCeramic. The DuraCeramic warranty says it will be honored if the product is "professionally installed," so itÂs not clear that installation by our handyman would qualify. The information we have read online about flooring in general indicates that the manufacturers will try to duck warranty claims by blaming improper installation for any problems that arise.

Any advice for us?

Comments (7)

  • 17 years ago

    ALL of the flooring needs to come out...ALL of the lauan plywood; insist that it be done!

    Then...find a reputable retailer to sell and install the flooring and the recommended underlayment plywood.

    Although installing flooring is not 'rocket science'...you would be amazed how easily it is to screw up; that is why competent, trained installers get top dollar for what they do. Untrained laborers and the occasional hanyman can get the job done, but that risk will be entirely yours if you go that route. However, if you have confidence in your handyman and he can follow ALL written directions that come with the product, then perhaps that might be the way to go for you...if you can't find a retailer/installer who instills confidence.

    In my opinion the only warranty claim you will void is any defect due to improper or faulty installation. As far as I understand the law, a manufacturer cannot void a 'material' warranty simply because a product was not professionally installed.

    It is indeed sad that the flooring business does not have more skilled and trained installers, but it has been that way for as long as I can remember.

    Get the underlayment out and quiet those sqeaks now. No one in his right mind will guarantee that those sqeaks will never return or new ones appear as the seasons change.

  • 17 years ago

    Glensfc, thanks for the reply. I would dearly love to find a competent trained installer and would willingly pay top dollar. Unfortunately, even after finding a KD/GC who came with high recommendations (we talked to about a dozen former clients before signing the contract), it seems that with a few hours research on the web, we know more about the various aspects of our kitchen remodel than most of the sales and trades people we have come in contact with. Most of them just say "yeah, yeah, yeah, I know", then start to do exactly what I don't want them to do.

    We'll try a few more flooring places, and if we can't get a good feeling from any of them, I think we will go with our design/build guy, and go over the entire DuraCeramic installation manual with him before letting him start.

  • 17 years ago

    words to say often:

    'my floor, my money, my way' or 'my house, my money, my way'

  • 17 years ago

    Where are you in the US?

  • 17 years ago

    We are in the MD suburbs of DC.

  • 17 years ago

    On the sixth try, we finally found a flooring guy who seems to know what he is talking about. He came out to see our kitchen after demo and after removal of the water-damaged subfloor. He pointed out that we have (upward of the joists) 5/8" plywood, 1/2" plywood, original sheet vinyl, lauan, and newer sheet vinyl. He guessed that the second plywood layer was installed to raise the the original sheet vinyl kitchen floor up to the level of the adjoining dining room hardwood.

    The KD/GC had removed the "old floor," per contract, down to and including the original sheet vinyl, and removed and replaced the water-damaged part of the subfloor. The joists were fine.

    The flooring guy said the white stuff remaining on top of the undamaged subfloor was NOT underlayment like I had thought - it was a thin paper backing of the original sheet vinyl that had been glued to the subfloor and did not come up when everything else down to the original vinyl was removed. The staples had been put down through the lauan and original vinyl before laying the new vinyl, and remained after the GC had pulled up everything down to the original vinyl.

    The flooring guy recommended screwing down the two layers of subfloor into the joists to get rid of squeaks and remove or pound down the staples, then sand and level the subfloor. Then install either (1) 6mm Halex followed by the DuraCeramic, or (2) float the DuraCeramic using the Congoleum flexible UnderFlor(TM) underlayment. He recommended the Underflor. When I said I wanted a very stiff floor, he said the 1 1/8"total of the two layers of plywood subfloor would provide plenty of stiffness, and when well screwed down, would be just fine.

    This sounds OK to us - anything we should question? If the price comes in anywhere near reasonable, we think we will go with this guy.

  • 17 years ago

    I am involved with a big time congoleum store that specializes in Duraceramic and the fellow your dealing with sounds right on the money. He said all the right things.