DIY Network

Natural Cork Flooring Installation From "DIY to the Rescue" episode DTTR-511F

The DIY to the Rescue crew is at the home of self-employed seamstress Trudy Dinnhaupt and her husband, Ken. Host Karl Champley instructs Ken and Trudy on how to cover the sewing room's existing vinyl floor with a new floating system of natural cork planks.

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	There had been a motley vinyl floor before the DIY to the Rescue team arrived.
	Hosts Carl Champley and Amy Devers got to work and installed a beautiful cork floor.
	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

Materials:

cork floating floor planks
1/2 inch spacers
flexible caulk
cleaning supplies
trim
6 mil polyethylene sheeting (optional)
table saw and measuring tools
Natural Cork tapping block
Floor pull bar
Jig saw

Natural Cork Flooring Installation

Note: Start installing the floor in one corner, preferably parallel to the longest wall and following the direction the light falls (figure A). It is equally possible to work from left to right or right to left.

Note: Always insert the tongue into the groove, not the other way around.

1. Choose the longest wall that will be parallel to the plank floor. Tap a nail part way into the old floor 1/2" from the wall at each end of the room. String a line between the nails 3/4" above floor level. Use this string as a guide line for the first row of planks (figure B). The 1/2" space from the wall allows room for expansion. Shuffle Natural Cork planks for best visual mix.

2. Facing the guide line, place the first plank at the lefthand end, tongue side facing wall, starting 1/2" off the wall (figure C). It is necessary to remove the tongue from all planks lining the starting wall. Use 1/2" spacers at the end and along the wall (two to a plank) while keeping the planks aligned with the string. Spacers keep planks from shifting when subsequent rows are added. Using Natural Cork tapping block and a hammer, place block flat on floor, with the side up that is labeled: "This Side Up For Tapping On Groove", tap on block gently until the ends of the two planks are firmly joined, with the joint completely closed up (figure D). Continue this process until you reach the end wall. Cut the last plank to fit allowing for a 1/2" perimeter expansion space on all sides.

Note: To do this, you will need a hammer and the special Natural Cork tapping block. Do not use any other tapping block (figure E). Using any other tapping block may result in damage to the cork wear layer. You should not attempt to knock the click joint into place with one hit. Once the two planks have "clicked" together, do not tap them again as this can cause the joint to be too tight and result in peaking.

3. If the cut-off piece from the previous row is more than 10" long it can be used to start the next row so long as end-joints between adjacent rows are always staggered by at least 10". Firmly holding row one in place, (a weight such as a full pack of planks may be helpful).

• Position the long side of the plank to be installed at an angle of 20-30 degrees to the plank already installed. Move the plank to be fitted slightly up and down at the same time as exerting forward pressure. The planks will then click into place (figure F).

• Using Natural Cork's tapping block, use a number of smaller taps on the short edge until the planks click together completely.

• In some cases, the planks cannot be rotated into one another, for example under a doorframe. In cases such as this, the planks can be fitted horizontally. For the long edge, you should tap them together gradually: begin tapping lightly at the corner of a plank until the join is made, then repeat the process every 12" until the entire long edge of the plank has clicked in with the other. In order to cut around pipes, take a drill bit with a diameter similar to the diameter of the pipe + 1/4" for expansion (figure G).

4. Usually the last row will require all planks be cut lengthwise. Measure each plank at several places along the length to ensure a proper fit. Remember to allow a 1/2" expansion space along the wall side. Use floor pull bar and mallet to click the long side of planks. The short edge can be joined using the tapping block.

5. After installing your floor, you can immediately walk on it. This is one of the major benefits of the uniclic system. Remove all spacer blocks. Fix the skirting board over the extended polyethelene sheeting. Never attach skirting board to the floor itself, but allow space for the floor to expand and contract beneath the skirting board. In order to fill in the expansion gap around pipes and any other areas not covered by trim, use a flexible caulk.

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