Hicksville, N.Y.—For many retailers and consumers cork flooring is a relatively new concept. But, as we discussed in part one of this series, it is a product that has actually been around for generations. In fact, in the early part of the 20th century, it was one of the more popular floor covering materials. Over the years, cork’s popularity waned as other flooring materials came into play. But, thanks in part to technological advances and a renewed interest in environmentally friendly products, cork is once again gaining the favor of consumers and designers.

The newest generation of cork floors are “floating” or glueless products. They have been available for about the past seven years, but only commonly used for the past three to five years. They are composed of a thin decorative cork veneer on a fiberboard or engineered wood substrate. These install much like laminate floors that essentially float on top of the subfloor. These loose-laid products can be installed as D-I-Y projects or be professionally installed. The pluses of a floating floor include the ability to install over subfloors that are not perfectly flat. Ironically, cork is also used as an underlayment for floating cork and laminate floors.

Cork’s sound absorbing qualities reduce the “tica tica” sound that sometimes results from subfloor and floor contact when the floors are walked on. One of the newer floating cork floors is Moderna Toledo, from BHK. Ken Riley, director of sales, said the floor was introduced at Surfaces to a “great reception,” and is now available nationwide. In addition to being a floating floor, it features the patented Uniclic mechanical locking system, “making it a snap to put together.” He summarized the advantages of this type of product as “a simple, fast installation with easy maintenance.” The 100% cork surface layer is UV acrylic finished and provides significant acoustic insulation. Toledo, which is available in five patterns, can be installed over most other floorings.

Another new generation floor is from Amorim—the glueless Cork-Loc plank marketed under the company’s Ipocork brand. It attaches “like a jigsaw puzzle,” said the mill’s Joaquim Mota. “Consumers can use the floor immediately after installation, and if the need arises, the pieces can easily be taken apart and removed.” Different Finishes Floor finishes affect the look and the durability of the product. There are four basic options: unfinished, wax, acrylic and urethane. Unfinished or sanded products are typically used on tile products (see part one, FCNews April 29/May 6, for more details on cork tiles). Unfinished products need to be sanded and finished prior to use.

There are waxed finished tiles and planks. “These are generally solid carnauba or oil-modified finishes that need to be reapplied periodically” said Rob McKee of Expanko Cork. “Waxed floors are appropriate for residential use, but do not have the durability needed for commercial traffic.” Despite acrylic coated products having more durability than waxed, they are still recommended for residential use. For commercial applications, and for the ultimate in durability for residential use, polyurethane-finished products have the strongest wear resistance. The urethane finish is tough, but like all floors under heavy use, it may need to be reapplied periodically to ensure the floor underneath is not damaged.

While natural, untreated cork floors require occasional refinishing and re-waxing to restore pattern and luster, just as any wood floor, urethane-coated cork floors should never be waxed. For residential use, “Our tile product comes waxed, varnished or sanded, to give the customer the choice” said Steve Tolli, technical advisor for Ipo-cork and its sister brand Wicanders. “Natural products need to be sanded and finished on site, waxed products should be waxed routinely, and varnished products are factory sealed.” McKee is also emphatic about selecting the right finish. While there are lots of options for consumers, “only urethane finishes are durable enough for commercial use.”

Unique Installation Issues Here’s where being a wood product, while at the same time being a resilient floor with tile or floating floor construction, creates some interesting installation dynamics. Like wood, cork has natural tendencies for expansion and contraction, and can be affected by high levels of moisture. Like resilient, it is easy to install the tile formats, and easy to cut into shapes for custom designs. Like a laminate it can be installed over imperfect substrates. Cork is also easy to cut with a utility knife. Like most manufacturers, Expanko is adamant about quality installations, as McKee explains: “Cork is not a commodity. There are varying degrees in quality, and you get what you pay for.”

When selecting cork, his advice to consumers and specifies is to “find out how long the company has been in business, because experience is important.” He noted the experience is necessary to fully understand how to install cork correctly over varying substrates. “If the company has no technical service, as Expanko does, how can they help you with installation and maintenance issues?” Maintenance Think hardwood, and you’ll know how to keep a cork floor looking its best. Ann Wicander, president of WeCork and no relation to Amorim’s Wicanders brand, said, “Cork is a wood product. Treat it like you would a wood floor and it will last a very long time.” Entrance mats will help remove dirt and moisture before they have the chance to damage the floor. Routine sweeping and vacuuming to remove dirt and grit that can scratch the surface are essential. Spills, especially staining liquids, should be mopped up with a damp cloth or sponge. Occasional cleaning using a damp mop moistened with a neutral pH detergent diluted in clean water will keep the floor clean and sanitary.

Remember that being a wood product, too much water or cleaning liquid can damage a cork floor. Charles Helton, director of Arcobel USA Corp., asked, “Got pets? Then remember to keep the polyurethane surface or polished surface maintained properly to eliminate scratch marks that may occur from nails.” Applying an additional coat of polyurethane after installation to seal the floor, and proper maintenance using polish once or twice a year will ensure the longevity and beauty of the product. When properly maintained, cork floors will last as long as wood floors in residential and commercial applications. It is not unusual to find cork floors in homes that date back to pre-vinyl times. They may have darkened with age, but they may also look and perform with like-new characteristics.

Many commercial installations, including places of worship and libraries have cork flooring that has lasted for over 75 years, and is still going strong. Wicander said, “If you finish and maintain a cork floor like a hardwood floor, it will wear better than hardwood because wood is harder, and therefore easier to mar. Cork will recover better.” It also has the advantage of self-healing when damaged by sharp objects. Areas that don’t self-heal can easily be fixed with wood filler. Tough Stuff Cork flooring is very durable. Many people think walking on a cork floor is akin to walking on a bulletin board—a true high-heeled disaster. However, cork flooring’s density can withstand heavy traffic and weight. The floors are manufactured to perform in residential and commercial traffic areas.

Tolli of Wicanders and Ipocork said the finish has a lot to do with durability. The contract floors Wicanders introduced at Surfaces 2002 have PVC wearlayers for commercial durability. Its Cork O Floor and Wood O Floor are floating floor systems as well. “PVC wearlayers are great for commercial use, as they add durability.” Proof of cork’s durability is not buried in museums, although it can be seen in them. Some of the more prestigious and older installations that are still intact include Chicago’s First Congregational Church, installed in 1890; The Mayo Clinic, installed in 1890, and the famous Frank Lloyd Wright residential project, Falling Water, installed in 1937. More recent, notable installations include the Library of Congress and several Fortune 500 corporations.

Even Cork Has Limits All resilient and hardwood floors can be damaged, as can any floor covering. But, like everything else in this world, with a little precautionary help and common sense, damage can be minimized. Heavy stationary furniture that can dent the floor should have protectors or pads placed under the feet. All the companies FCNews spoke with for this article do not recommend cork for use below grade level or in basements because of potential moisture problems. If the subfloor has a moisture barrier in place, floating cork installations may work, but the total installed price becomes cost prohibitive. Better to use cork for high profile and above ground spaces, say most manufacturers and distributors.

Cork’s closed cell structure is a good barrier against moisture (think of the role cork stoppers play in wine bottles). But the floor top and bottom can absorb moisture where the cells have been opened from sanding, cutting and installation preparation. Moisture that enters those open cells can cause cork to swell, causing tiles to delaminate off the subfloor and to cup. Above all, remember that cork is a wood product, so as with any hardwood floor, excessive amounts of moisture or water can affect it in an adverse way. Basements, ground level slabs and subfloors that have a high moisture level or are prone to flooding are not good areas to install cork flooring.

What’s Next? Consumers and specifiers owe it to themselves to learn more about the products to make the right selection. Even more so, dealers owe it to their customers to learn as much as possible in order to make sure they are carrying and selling the right products to fit their clients’ lifestyles. The proverbial knowledge is power is as true here as it is for any product. McKee said the future will most likely see more products and installation systems but fewer large players in the cork business. “The quality manufacturers, service-oriented distributors, companies with good technical assistance, good installation systems and good warranties will dominate.” As for forms and installation, Helton called the new “easy click systems for floating floors” the growth market. Amorim’s Mota confirmed that his company, a long-time industry leader in cork floors, “is continually focusing resources on new colors and patterns to stay in step with the trends of today and the future.”