Home Movie Theater Carpet - Empire | Joy Carpets

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Carpet Installation Guide

Joy Carpets recommends using a certified professional for all installations. Before you begin, inspect the carpet for any visible defects. The manufacturer is not responsible for issues discovered after the carpet has been cut or installed.

Stretch-In (Over Cushion) Installation

Condition the carpet: Lay the carpet flat and let it acclimate at a minimum of 65°F (18°C). Installing below this temperature will require extra effort to stretch the carpet.

The final installed temperature should be between 65°F and 85°F (18°C to 30°C) to prevent wrinkling.

Stretching the Carpet

• Stretch synthetic-backed carpet more than jute-backed.
• Stretch evenly in both length and width directions.
• Aim for a minimum 1% stretch in both directions, which is about 1.5 inches per 12 feet.
• Follow the 7-step power stretching procedure outlined in the original document, which details a specific sequence for stretching and hooking the carpet into corners and along walls using a power stretcher and knee kicker.
• Measure the stretch: Use chalk to draw a line near the wall and measure how much the mark moves as you stretch. This helps ensure a uniform 1% stretch.
• For large areas, subdivide the space and stretch each section separately.
• Caution: Do not install over existing carpet.

Cushion Recommendations

Residential: Maximum thickness is 7/16" (11.2mm).

Bonded Polyurethane: Minimum density 6.5 lbs/cu.ft.

Prime Polyurethane: Minimum density 2.8 lbs/cu.ft.

Needled Synthetic (felt): Minimum density 32 oz/sq.yd.

Commercial:

Needled Synthetic: Minimum density 40 oz/sq.yd. Maximum thickness 3/8" (9.5mm).

Slab Rubber: Minimum density 18 lbs/cu.ft. Maximum thickness 1/4" (6.4mm).

Note: Using the wrong cushion is a major cause of installation failure.

Seaming Procedures

Hot Melt Method: The recommended method for strong seams.

Seaming Tape: Use a high-quality tape. Orcon Super 3 and K-80 or Roberts GT-350 are recommended.

Equipment: Use a seaming iron with a heat shield to prevent damage.

Seam Sealer: All cut edges must be sealed. Milliken "Barrier Bond" seam sealer is recommended.

• Direct Glue-Down Installation
• Adhesives: Use Milliken Broadloom Carpet Adhesive for all ActionBac® and attached cushion products. This is a CRI "Green Label" product.

Coverage:

Direct Glue: 10-15 sq.yds. per gallon with a 1/8" x 1/8" x 1/16" V-notched trowel.

Double Stick: 6-8 sq.yds. per gallon with a 1/8" x 3/16" x 1/8" U-notched trowel.

Floor Preparation

• Ensure the floor is clean and free of dust, grease, paint, or old adhesive.
• Fill cracks and smooth out any protrusions. The surface should be smooth within 1/8" in 10 feet.
• Test for alkalinity and moisture. Concrete pH should not exceed 9.0.
• Moisture vapor transmission must not exceed 3 lbs per 1000 sq.ft. per 24 hours. The manufacturer recommends professional testing.
• Concrete sealing is generally not needed for properly cured floors but may be required for porous or dusty slabs.

Installation Procedures

Adhesive: Use the correct trowel size and coverage rate. Insufficient adhesive is the #1 cause of failure.

Patterned Carpet:

For direct glue-down, the manufacturer is not responsible for pattern match.

Determine the installation sequence based on pattern repeat size.

Use hot melt seaming tape (Orcon K-80) to secure pattern match, especially in double-stick installations.

Non-Patterned Loop Pile: Row-cut one edge, overlap, and scribe-cut the second edge. This method is not for patterned carpets.

Seams: Bead all edges with seam sealer.

Application: Lay carpet into the adhesive, working from the center outward to avoid air bubbles.

Rolling: Roll the entire area with a 75 lb. roller in both directions.

Curing: Restrict heavy traffic and furniture for 24 hours.

PROFESSIONAL CARPET CLEANING:

A reputable professional carpet cleaner is knowledgeable on the latest carpet construction, carpet care products, and safe cleaning methods. Contact a carpet cleaning professional when soil and stains are no longer removable with vacuuming and recommended carpet cleaning procedures. Obtain the name of a reliable carpet cleaning professional through referrals, the Better Business Bureau, or contact the Carpet and Rug Institute (706.278.3176) for a list of cleaning professional members and a copy of the Carpet and Rug Care Guide (www.carpet-rug.com).

RECOMMENDED CLEANING METHODS:

The consumer should rely on the carpet manufacturer's recommendation. Select cleaning agents sold especially for soil and stain-resistant carpet and FOLLOW THE DIRECTIONS FOR DILUTION AND APPLICATION. Never use soap, ammonia, laundry detergent, automatic dishwashing detergent, washing soda, or any strong household cleaning agents intended for use on hard surfaces, i.e. woodwork, linoleum, tile, as these cleaning agents could damage carpet. For best cleaning results, always pre-vacuum. Clean spots promptly.

• Hot Water Extraction - Pressurized hot water is injected into the pile. Suspended soil and solution are immediately extracted by a powerful vacuum. FOLLOW DIRECTIONS CAREFULLY. Avoid overwetting and excessive high temperatures (over 120°) and ensure speedy drying. Properly performed by carpet cleaning professionals, hot water extraction will effectively remove accumulated soil from the carpet and refresh the texture.

• Dry Extraction - An absorbent compound (Capture® Rug Cleaning System) is brushed in and around the fibers. The compound attaches to soil particles and both the particles and compound are then removed by vacuuming. Follow specific Capture® Rug Cleaning System instructions.

SPOT CLEANING:

First do a general cleaning and then, if necessary, spot clean. Pretest anyspot removal or cleaning agent in an inconspicuous area to make certain the solution will not damage yarns or 2 dyes. After applying several drops to the testing area, hold a white cloth on the wet area for ten seconds. Examine the carpet and cloth for color transfer, color change, or damage to the carpet. If a change occurs, select another cleaning solution.