There are many kinds of formulations and methodologies with today's adhesives.

By K.J. Quinn
The proliferation of new floor coverings from around the world—namely exotic species, bamboo, cork and tile—has challenged adhesives manufacturers to develop compatible bonding systems. And with a constant flurry of new products, experts say, it makes keeping tabs all the more challenging.

“So much flooring is imported into North America that differentiating between domestically produced and imported products is like calling a 2007 Toyota a foreign car,” said Greg Wood, president of Advanced Adhesive Technologies ( AAT). “Bamboo, cork, vinyl tile, sheet vinyl and others are all in the mix.”

Indeed, the heat is on the adhesive industry to develop formulations that ensure successful installation of imports. Suppliers say significant investments are being made in R&D to ensure the latest bonding systems comply with both flooring manufacturer specs and regulatory requirements. “Keeping up with the changes and trends in new flooring materials and developing adhesives and systems to meet these demands has definitely been a challenge,” said Rick Wolf, business manager—floor covering installation systems at Mapei. “To meet these challenges, Mapei has invested 12% of our workforce to research and development. We also include installation training for many of these new flooring materials as part of our seminars at the Mapei Technical Institute.”

Para-Chem reports making a substantial investment in research, equipment (for testing) and field testing. “A year ago, we invested in a testing chamber that simulates extreme conditions that may be found on a job site,” said Cathy Panagakos, vice president, Parabond division of Para-Chem. “We also go to the contractor, distributor and flooring manufacturer and demo these products.” Para-Chem recently developed a Transitional Pressure Sensitive Adhesive for an imported luxury vinyl tile and vinyl plank that evolved into the Fusion Series 5082.

W.W. Henry, too, has invested heavily in increased R&D resources to test the higher number of floor structures entering the country and to formulate products that ensure the long-term success of the flooring installation, according to Michael Crouch, executive vice president. In addition, Ardex and Henry claim to maintain the largest investment in technical service and installation training in the industry. “This is critical for retailers and contractors, as this is a resource they can take advantage of in order to get updated on new products, structures and installation systems,” Crouch said.

Observers say the rising number of exotic wood species and solid vinyl floors, in particular, entering the U.S. is creating new opportunities as well as challenges for adhesive makers. Many of the new floor structures are less dimensionally stable than traditional wood and vinyl products. “The biggest change is to new types of solid vinyl structures that have different types of vinyl backing,” Crouch observed. “Many new types of imported wood species react more aggressively to climate changes than traditional wood structures.” The new Henry 422 adhesive was developed, in part, to help minimize problems associated with newer, imported solid vinyl plank and tile structures.

Indeed, glue makers are tinkering with two of the leading formulative technologies—waterborne and moisture-cured urethanes (MCUs)—as part of an effort to create more environmentally compliant systems while meeting the bonding needs of imported products. Some R&D efforts focus on bolstering moisture and alkali resistance, cross-linking and solids contents for waterborne adhesives. Meanwhile, MCU glue makers are attempting to improve trowel ability and clean up, characteristics offered by water-based products. By utilizing existing technologies, adhesives makers can bypass costly R&D investments associated with developing new, alternative chemistries.

“The variety of raw materials being used in floor covering has stretched our challenges to find new raw materials that are compatible and remain consistent,” Panagakos said. “Development or reformulation of adhesives to encompass this new challenge then needs to be field tested and data bases are being built upon that research.”

The fact that changes in adhesive technology and performance characteristics are occurring so rapidly means it is increasingly important for flooring contractors, retailers and installers to be aware of factors impacting installation, experts say. Therefore, it is imperative industry members stay current on the latest adhesive information. If they choose not to be informed, the risk of job failure drastically increases.

“It is important to take advantage of the seminars and classes offered by the flooring and adhesive manufacturers as well as attending industry and trade events,” said Audrey Chapman, associate product manager—floor covering installation systems at Mapei.

Each formulation produced by adhesive makers is unique, and many factors affect specification, such as temperature, humidity and porosity of the subfloor. There are many kinds of formulations and methodologies capable of bonding or joining various substrates, which makes it essential for installers to understand suppliers’ product lines. “Flooring retailers and contractors should take advantage of installation training from their suppliers, read as much as they can from the various trade publications, and work hard to be a ‘continuous learner,’” Henry’s Crouch suggested. “It will only benefit themselves by reducing claims and increasing profits.”

Further complicating matters is a fragmented customer base that adhesives marketers and distributors find difficult to reach. In addition to installers, this mixed bag includes flooring retailers, contractors and workrooms. Adhesive makers say they have this covered by providing, among other things, training, marketing and merchandising support. Plus, they sponsor and participate in training programs with flooring manufacturers, distributors and trade organizations.

“The flooring community has an effective infrastructure for communicating proper adhesive selection and usage,” AAT’s Wood said. “However, the fragmentation of our industry sometimes makes our effective communications less efficient.”

Adhesives selection

So how do retailers and installers determine which products work best with imports? Determining the type of adhesive to use often depends on the manufacturer’s specifications. If the recommended glue is not used to install the floor, it may void manufacturer warranties. “A good rule-of-thumb is to read application directions,” said Robert McNamara, national sales and marketing manager of Bostik’s Flooring Group. “If they are similar to ‘old technologies,’ they may not be too different. However, some of the best product development allows for greater job site flexibility with few changes to application techniques.” He noted that Bostik is working to make its products more “job-site friendly” yet versatile enough to address a host of application challenges and variables.

Oftentimes the flooring manufacturer will offer a recommendation for the type, or in some cases, a specific adhesive to use when installing a particular floor. “We have found, however, that in some cases, some of these new, smaller manufacturers don’t have complete knowledge of how their products should be installed,” Henry’s Crouch said. “In some cases, we are creating installation systems for new imported products, especially for those companies that do not have knowledge about substrates and installation conditions in the U.S.”

There are other variables impacting adhesive specification, namely geography. For example, temperature requirements and/or increased air emissions affect the use of waterborne products. Meanwhile, price remains a prime consideration of cost-conscious installers, experts say, although vendors claim the latest products are competitively priced.

“My best recommendation is for the individuals responsible for the specification to ask a lot of questions,” AAT’s Wood suggested. “Ask the distributor, manufacturer or importer of the flooring about their adhesive recommendations, and then ask for their preferred adhesive vendor.” AAT develops adhesives for all types of imported floors which are sold under the AAT and importer/manufacturer brands.

When in doubt, installers and retailers can contact the technical services departments of adhesive manufacturers to recommend which brand products are suitable for flooring installation. Vendors say they stand behind their products if used in place of an adhesive recommended by the flooring manufacturer. “Mapei’s technical services department can also assist flooring manufacturers with compatibility testing of their products with Mapei adhesives and provide manufacturers with written recommendations for Mapei products with their brand(s) of flooring,” Wolf said.

Acceptance levels for the latest adhesives vary, as there remains a contingent of installers who are more comfortable working with tried-and-true formulations. Meanwhile, price-sensitive mechanics may purchase the least expensive glues to minimize their own costs. Suppliers contend if the installation community uses recommended bonding solutions from reputable companies they will work very well.