This column is significant for two reasons: It is the 500th “Claims File” I have written for FCNews in 20 years and the new technology I am writing about will have revolutionary implications for carpet installation.

Free Lay is a completely unique backing system that allows the installation of attached cushion broadloom without the use of adhesives or tack strip. The only steps necessary are for the substrate to be completely clean and dry, the alkalinity should not go above 10 ph and a polymer must first be applied when used on concrete, plywood, metal or particle board. But, this system can be installed over hardwood, vinyl, vinyl tile, terrazzo, granite, marble, polished concrete and ceramic without polymer.

Basically, the system is like how a fly sticks to a wall. The active film on the backing material forms a bond on the polymer or flooring material, allowing the carpet to stay in place. The broadloom will not move laterally but it can be easily lifted. The longer the carpet stays in place, the stronger the bond becomes until it reaches maximum adhesion. The bond never becomes permanent and the flooring material can be easily removed without any substrate damage.

Free Lay can be used on broadloom, carpet tiles and rugs. It can also be applied to any synthetic or natural carpet. The broadloom can be worked on, if necessary, to adjust things such as pattern alignment.

The significance

This backing system requires no adhesive, no tack strip and no stretching. It can be pre-cut to fit the desired areas without compromising hardwood, vinyl, stone, ceramic, terrazzo or painted concrete substrates. It will allow the carpet to resist buckles, wrinkles, puckering, seam peaking—all issues that have created complaints and claims in the past.

No longer is there concern about adhesive failure, lack of enough adhesive, improper or inadequate stretching, etc. The carpet becomes dimensionally stable. There are no VOCs to be concerned with, nor any odd or unpleasant adhesive odors. It allows for free-form designs, nearly invisible seams and no seam peaking or discoloration from seaming irons and tape, which do not have to be used. Installations become faster and easier.

If this sounds too good to be true, well, it almost is. The technology was invented 10 years ago, was patented five years ago and we have been working with it for over five years during which we have tried to make it fail and it hasn’t. Carpet with this backing system can be installed in homes, businesses, offices, medical facilities, veterinarians’ offices, and indoor golf instruction facilities. It is used in manufacturers’ facilities, retail showrooms, churches and schools. We have purposely looked for problem sites to install it and it has always performed flawlessly.

Any manufacturer producing any type of carpet can use this backing technology. This is a huge statement but, when used correctly, it will get rid of almost every installation problem you’ve ever had. All the components normally used that can cause an installation to fail are eliminated. The industry can say goodbye to claims of buckles and wrinkles associated with failed stretch or direct glue-down installations. Any type of broadloom for both residential and commercial locations will benefit from the Free Lay technology system.

This is the first public announcement of Free Lay. The more we work with it the more amazing it becomes.