Reversible Interlocking Flooring Installation / Maintenance Guidelines

Ironcompany rubber mat flooring is a high quality recycled product. In order to enjoy your new floor fully, proper installation procedures must be followed. The following installation tips are guidelines only... please read this manual before laying Ironcompany flooring products.

On receipt of merchandise:

Note:

Rubber will expand and contract with temperature and humidity changes. (see Section lll, 1)

Petroleum distillants (e.g. solvents) will damage tiles. See test results for other harmful chemicals.

Keep Ironcompany flooring products dry. 

Improper installation will void warranty.

CONTENTS

Section

 

I

Tools & Accessories

II

Preparation of the Sub-Surface

III

Before Starting the Installation

IV

Installing Sport Mat Flooring

V

Installing Ironcompany Flooring

VI

Measuring & Cutting the Mats

VII

Adhesives (not needed for interlocking flooring)

VIII

Sealer (N/A)

IX

Cleaning & Maintenance

X

Disclaimer

XI

Weights & Measures

Section I   Tools & Accessories

Tools and safety  equipment  required:

  • Safety glasses
  • Knee pads
  • Utility knife
  • Measuring tape
  • Straight edge
  • Chalk line 
 

B) Outside interlocking edges

With interlocking Sport Mats, Ironcompany includes approximately 10% of the outside edging with every order, unless otherwise requested. This edging gives the interlocked mat a straight edge so reducer strips can be applied. It can also be used against walls, where possible, to avoid having to cut tabs off.

C) Reducer strips

Ironcompany carries four types of reducer strips:

  • 5/16" (8 mm) black solid core  (12' lengths)  
  • 3/8" (10 mm) black solid core  (12' lengths)
  • 1/2" (12 mm) black solid core  (12' lengths)
  • 3/4" (20 mm) black solid core    (12' lengths)  

    Attach reducer strip to mats with compatible adhesive or caulking, non-solvent based.

    E) Sealer

    For most installations it is not necessary to seal or coat Ironcompany Sport Mat Flooring. Sealants and waxes may alter the surface characteristics of the mat. If the customer requires a sealant, see section “VIII Sealer".

    Section ll     Preparation of the Sub-Surface

    A) Concrete sub-surfaces

    New concrete sub-floors must be thoroughly cured and free from hydrostatic pressure before Ironcompany Sport Mat Flooring is installed (a minimum of 28 days after pour).  Consult adhesive specifications for allowable moisture tolerance.

    If existing concrete is too rough, apply a Portland cement based leveling compound for a smoother surface, allowing a minimum of 7 days for curing. If finishing cement is not used, the amount of adhesive needed will be greater. Once all surfaces are level, make sure total surface is clean and dry before starting the installation.

    If the concrete surface has a layer of paint, dirt, oil, or contamination, a 25% solution of chemical grade muriatic acid and water (1 part acid to 3 parts water) will create a permanent bond by roughing the concrete surface. Rinse thoroughly and allow to dry. Any separation of concrete layers, heaving, etc. is the sole responsibility of the installer and/or owner.

    Insure good drainage of the area by having either a well defined gradient of the surface, or well placed drainage pipes in the lower spots.

    Important:

    Moisture is the single greatest cause of bonding failure! The sub-surface must be clean and dry. A rough or uneven sub-surface will result in an uneven appearance of the rubber flooring.

    B) Wooden sub-surfaces

    Rubber mat installations over a wooden sub-surface are not ideal, as trapped moisture may cause deterioration and premature rotting of the wood. If this type of installation cannot be avoided, the following recommendations must be followed:

    Recommendations for plywood sub-surfaces are as follows:

    • Plywood underlayment shall be exclusively COFI EXTERIOR "SELECT TIGHT-FACE" (SEL TF) grade plywood according to the COFI classification and conforming to CSA-0121(B+CC) standard for Douglas fir.
    • Plywood surfaces must be installed smooth face up.
    • When the subfloor is in direct contact with the ground, the plywood shall have at least an 18” (45 cm) cross-ventilated air space between the underside of the floor and the ground.  Under no circumstances shall any floor material be laid over wood or subfloors that are subject to conditions which might cause buckling or rotting of the wood.
    • On any soft floor covering installation, the plywood shall be dry and the moisture content shall not exceed 10% when measured with "Delhmorst Wood Moisture Tester".
    • Plywood substrates shall consist of a ¾” (19 mm) thick (minimum) plywood underlayment. Each sheet of plywood is to be spaced 1/16” (1.6 mm) apart.  For additional information, refer to Table I in "Recommended installation specification for sheet vinyl flooring, flat laid, fully adhered to the floor" published by the Resilient Floor Covering Institute or to the NFCA's floor covering specifications manual.

    Note: Wooden sub-surface installations are at the sole risk of the installer, general contractor, or owner.

    Section lll   Before Starting the Installation

    1. Rubber will expand and contract with temperature and humidity changes and a mat laid in the morning hours at 32°F (0°C) would be a different size than a mat laid at 68°F (20°C) later in the day.  Therefore, before starting the installation, lay out ALL the mats you will be installing on the next day, on or near the sub-surface. Allow mats to equalize to ambient temperature.
    2. The sub-surface must be level, clean, and dry. It is recommended that all concrete slabs be tested for hydrostatic pressure.  Simply test by placing a rubber mat 2x3 ft (60x100cm) over concrete and tape edges.  Moisture or dark areas that are noticeable under a mat after 24 hours indicate that the area is not considered to be dry.
    3. During storage, Ironcompany Rubber Tiles must be kept dry, and adhesive must be stored above 50°F (10°C) in a dry, heated space.
    4. Check the room temperature.

      a) Temperature range for adhesive use: above 50°F (10°C) and below 104°F (40°C)

      b) In-floor radiant heat should be shut OFF. Glue will dry too quickly resulting in adhesion problems.

    5. Higher temperatures will increase the curing rate and reduce the working time (pot-life) of adhesive. Follow instructions on label of can!

    Section lV  

  • C) Interlocking system

      This method is for indoor, totally dry areas only.

    Advantages

    • reversible, thus doubling the life of the floor
    • no adhesive required
    • easier, faster installation
    • removable

    There are a few different options for the installation of the interlocking mats. It is not necessary to stagger the interlocking mats, although you may feel this will give you the appearance you desire (see figure 4).

    The staggered method is recommended to provide higher stability. When installing interlocking mats, make sure the interlocks are tight with no gaps showing. If they are not kept tight, the mats will not line up and the interlocking pattern will be distorted (out of alignment).

    1. Make sure that all mats are laid down with the “arrow” pointing in the same direction (see figure 4).
    2. The interlocking mats are delivered with outside interlocking edge pieces. The strips can be used to butt mats up tightly against a wall. The other option is to trim off the interlocking tabs for a snug fit.
    3. Sport Mats (square cut or interlocking) should not be laid on top of carpet as the floor will shift and move.

    Section V   Installing Ironcompany Interlocking Mats

    Please refer to Sport Mat Flooring installation for glue down method.

    Note: Install mats with ‘Made in Canada’ side down.

    Anchoring Ironcompany Interlocking Mats on concrete:

    • Position Ironcompany mats on surface with no space between them.
    • 16 to 20 nylon anchors should be used to hold each mat in place.
    • Use ¼” drill with masonry bit.
    • Drill hole through mat into cement, about ¼” deeper than the anchor (dust tends to go back into hole).
    • Hammer anchors into mat. Dip anchor into liquid soap first to make job easier. (see figure 5.)



    Section Vl
     
    Measuring & Cutting the Mats

    Any knife used for cutting Ironcompany mats must be sharp. Lay mat on a piece of wood (e.g. 2" x 4") hold the straight edge on the cut line, and cut with knife. Let the mat droop or hang over the edge of the wood base and keep scoring cut until separated. For odd angles, circular patterns, etc. a cardboard template is suggested.

    NOTE:  For cutting around posts, drains, etc. use saber saw. Make sure that you measure carefully so that the mat will fit properly and does not leave gaps, resulting in the installation being out of alignment.

    Section IX General Cleaning & Maintenance (no sealer)

    Typically, Ironcompany Sport Mat Flooring requires less maintenance than other types of flooring. Clean and maintain on a regular basis as required. Vacuuming then damp mopping is the preferred method, very little or no detergent is necessary.  Change water frequently.  Sealing or coating is not necessary and is based purely on the customer's preference. If a particular appearance is desired (shiny, dark wet look, etc.) Ironcompany recommends that the cleaning product used be “non-aggressive” (e.g. solvent and acid free). Products containing solvents and acids will attack the composite structure of the Sport Mat Flooring and cause deterioration. Sealants, waxes, etc. can alter the surface characteristics and appearance of the Sport Mat Flooring. Ironcompany does not assume any responsibility of additives causing damage to its surfacing.

    A) For fitness center applications:

    • When cleaning fitness equipment with disinfectant, or other strong cleaners, be careful that overspray or excess cleaner does not drip onto the rubber flooring. Strong chemicals may cause the surface to deteriorate, reducing the life of the floor.
    • Ironcompany suggests rotating the interlocking Sport Mats from high traffic areas to lower use areas to further extend the life of the floor.

    B) For ice arena applications:

    • Use a neutral pH cleaner, e.g. 7 – 8
    • Then use a cleaner, e.g. “Taski”, (the “Profi” solution -  3 to 4 oz. per gal. of water)
    • A low RPM scrubber, e.g. between 200 - 300 revolution per minute, e.g. “Clark”
    • Use a soft nylon brush, e.g. bristles 1½” - 2” long.

    Note: To find out if a brush is too hard, test it on the back of your hand. If your hand hurts, use a softer brush.

    The ideal machine to use is one that combines all steps, i.e. vacuum, wash, rinse, dry.  (e.g. Whittaker)

    If a scrubber machine is used, these steps should be taken:

    • Mix soap with water.
    • Use string mop to dampen floor.
    • Let solution act, (approx. 10 minutes).
    • Use scrubber machine.
    • Use clear water to rinse.
    • Remove excess water for quicker drying.

    Note: To maintain the nice appearance of the Sport Mat Flooring, dirty water must be completely removed.

    Section X   Disclaimer

    The installation guidelines in this manual represent a typical installation work procedure. Every site is different and Ironcompany does not claim to have covered all possible installation circumstances in these guidelines.

    Ironcompany.com, Inc. does not warrant any installation work not directly performed by Ironcompany, and specifically disclaims liability for any direct or indirect personal injury, property damage or other costs or losses resulting from installations or applications by third parties. Please see the Ironcompany Limited Warranty for the particulars of warranty coverage relating to Ironcompany products.

    Section Xl   Weights & Measures

    General packaging information:

    All Ironcompany products are packaged on wooden pallets, with corner protectors, polyethylene shrink wrap, and steel strapping (when necessary).

    A) Sport Mat Flooring:

    Dimensions:

    Square cut

    38”x38” (965 mm x 965 mm)

    10 square feet

    Interlocking

    37”x37” (940 mm x 940 mm)

    9.5 square feet

    Thickness:

    Typical weight per mat:

    Mats per pallet:

    5/32” (4mm)

    10 lbs (4.5kg)

    200

    ¼” (6 mm)

    16 lbs (7.3 kg)

    150

    5/16” (8 mm)

    20 lbs (9 kg)

    120

    3/8” (10 mm)

    23 lbs (10.5 kg)

    100

    ½” (12 mm)

    27 lbs (12 kg)

    80

    Pallet (net wt.)

    65 lbs (29.5 kg)

     

    NOTE: Weights are approximate and may change without notice.

    B) Ironcompany Mats:

    Dimensions:

    Square cut

    48”x72” (1219 mm x 1829 mm)

    24 square feet

    Thickness:

    Typical weight per mat:

    Mats per pallet:

    ½” (12 mm)

    80 lbs (36 kg)

    25

    ¾” (19 mm)

    100 lbs (45.5 kg)

    25

    Pallet (net wt.)

    75 lbs (34 kg)

     

    NOTE: Weights and measures are approximate and may change without notice.

      Conversion chart:

       1” =  2.54 cm,

       1’  = 30.48 cm 

       39.4” = 1m