Friday, October 7, 2011

Step 37 - Flooring










The major construction elements of the project are essentially completed. Our focus now is on the flooring, painting, and interior decorating. Let's start with the flooring.

We already had laminate flooring (by Wilsonart) in the living room, and we wanted to buy more of the same for the expanded area. However, we learned that Wilsonart decided to get out of the flooring business, so we had to go to Plan B.

Plan B consisted of taking up all the existing Wilsonart flooring, re-using it in other rooms, and buying all new laminate for the living room. Our contractors (Mark, Al and John) took up the Wilsonart and determined which pieces could be reused in the new office and Sheila's sewing room.

But before any flooring could be put down, it was necessary to get the floors level, especially the office. John Etchells did the leveling. First, he ground down the high spots. Next he mixed up some "dry pack" which is cement mixed with very little water. Instead of the usual mud consistency, dry pack comes out looking like corn meal. John spread it over the area to be leveled and packed it down firmly. When dry it gives a very hard and perfectly level surface. In other areas, self-leveling concrete was poured.

Now the flooring can go down. First is a layer of plastic vapor barrier. This keeps moisture from coming up through the slab to the flooring. Next is a layer of padding. Lastly, the laminate flooring was laid down. There is no gluing or nailing. This took care of the office and sewing room.

For the living room we bought Pergo laminate. The installation process was mostly the same as described above except that the pergo has padding already glued to the underside of the boards.

The end result is a good reuse of old material and a great new look for the living room.