DESIGN, MEET DURABILITY:

INTRODUCING A NEW GENERATION OF HYBRID VINYL PLANKS

www.heartridge.com.au

INTRODUCTION

UNDERSTANDING CONVENTIONAL HYBRID VINYL PLANKS

Across the globe, the popularity of hybrid vinyl plank is on an upward trajectory in the commercial and residential sectors alike. Floor Covering News reports that in the United States alone, sales in the wood plastic composite (WPC)/rigid core vinyl category have grown dramatically from approximately US$750 million in 2012 to $2.161 billion in 2016.1 According to an analysis of market conditions in the flooring industry by Catalina Research, WPC and other hybrid flooring options are the main product types driving growth in the hard surface category.2 Given its low maintenance qualities, hybrid vinyl plank has become a go-to option for homeowners looking for cost-effective flooring solutions in the residential sector.

Underpinning the growth and popularity of hybrid vinyl plank are market and industry-wide concerns with sustainability, installation

efficiency, health and wellness, and contemporary aesthetics. However, a number of performance shortcomings associated with conventional vinyl planks require close consideration. These shortcomings include a labour-intensive installation process and unsuitability for installation in areas where the installation environment cannot be consistently maintained within a small window of optimal temperature or protected from direct sunlight.

In response to these drawbacks, the design and construction industry has developed a new generation of stone plastic composite (SPC) hybrid vinyl flooring solutions that outstrip the capabilities of preceding products. In this whitepaper, we examine these SPC rigid planks and explore the advantages that they offer over conventional WPC planks.

WPC has been widely used in commercial applications since the early 1980s. However, it was not until the mid-1990s that companies in the United States created solid WPCs comprising approximately 50% wood fibre in polyethylene for specific use as flooring.3 Since then – particularly in the early 2010s – WPC has rapidly emerged as one of the most popular flooring solutions worldwide, taking market share from competing sub-categories within the hard surface market.4

In their early iterations, WPC planks were manufactured by combining plastic fibres with natural wood fibres, hence the product’s name.5 At present, WPC planks are typically constituted from foamed plastic, with the addition of tiny air pockets allowing for significant reductions in material weight.6 The benefits of lightweight and low density WPCs include ease of transportation and compatibility with small-scale, do-it-yourself projects. WPC offers significant benefits over traditional laminate or vinyl flooring solutions. In addition to retaining the visual appeal of a genuine natural material – which can be lost with other vinyl flooring solutions – WPC planks deliver sustainability, resilience, design flexibility, and cost efficiency benefits when compared with natural timber. In spite of this, WPC does fall short in a number of key performance categories, and thus merits closer consideration.

The design and

construction industry

has developed a new

generation of SPC

hybrid vinyl flooring

solutions that outstrip

the capabilities of

preceding products.

DISADVANTAGES OF WPC AND CONVENTIONAL VINYL PLANKS

The aesthetic, functional and cost benefits of conventional vinyl plank are easily negated by improper installation. A common issue with vinyl flooring in general is the amount of effort and time required to prepare the subfloor. Failure to properly prepare the subfloor can lead to “telegraphing”, an unsightly side effect whereby unevenness underneath vinyl planks reveals itself on the floor surface over time. While WPC planks can hide minor imperfections on the subfloor, uneven surfaces and substrate irregularities can complicate the installation process, creating gaps and poor fitting.7 Conventional vinyl planks that need to be glued down still require removal of chemicals, contaminants and moisture from the subfloor in order to avoid compromising the installation process.8

This need for adhesive in many conventional vinyl plank flooring systems can be problematic: selection of inappropriate or poor quality adhesive can cause costly post-installation issues including

gapping or peaking in the planks. Other WPC solutions feature a click or lock joint mechanism that reduces – if not completely eliminates – the need for adhesives, but which is susceptible to lifting at the edges when the planks have planar stability issues.9

This instability is compounded by WPC’s low resistance to extreme temperatures,10 which cause it to expand and contract.11 This expansion and contraction is particularly pronounced in areas subjected to direct sunlight, where vinyl planks are exposed to temperatures reaching nearly 50 degrees celsius depending on the time of year.13 When warmed up, vinyl planks expand, creating pinch-points and a ‘tenting-up’ effect.14 This lack of dimensional stability can significantly affect the floor’s appearance and durability.

Additionally, WPC is often more expensive than similar engineered materials suited to the same applications, such as resilient flooring and laminate.15

STONE PLASTIC COMPOSITE: A DESIGN-BASED SOLUTION

The new generation of rigid core vinyl solutions on the market uses a stone plastic composite (SPC) to overcome the key performance shortfalls associated with WPC. In particular, SPC planks are designed for maximum dimensional stability even when exposed to moisture and extreme temperatures.16

WHAT IS SPC?

SPC planks are multi-layered units comprised of a durable, thick core of natural limestone powder, polyvinyl chloride, and stabilisers that is sandwiched between two face layers of vinyl plank. By comparison to WPC planks, SPC planks have a dense and heavy core that affords them a high degree of durability.17 As such, SPC planks are highly resistant to expansion and contraction even in the face of humidity and fluctuating temperatures, and are equipped with a highly scuff- and abrasion-resistant surface layer. In addition, SPC products typically avail of glue-free construction that provides hypoallergenic qualities and eliminates harmful gas emissions.18

ADVANTAGES OF SPC OVER WPC

The high dimensional stability of SPC planks makes them an ideal alternative to WPC planks, particularly in complex and

demanding environments. SPC has all of the key benefits of WPC, such as design flexibility, versatility, resilience and streamlined installation, in addition to superior performance and durability. This is largely due to SPC’s limestone composition, which enables a denser, harder-wearing end product. SPC’s high-density core is more stable than that of WPC planks and immune to expansion and contraction; beyond this, SPC offers outstanding resistance to impact, scratches, and dents, making it suitable for commercial and residential projects alike.

SPC planks are also water-resistant and UV-resistant.19 As a result, they are suitable for installation in environments where sun exposure, temperature variations, or moisture are likely – environments for which WPC is inappropriate. SPC planks will not deform or degrade over time even with repeated exposure to extreme temperatures and humidity, and are thus ideal for installation next to windows and doors or in kitchens, bathrooms, and laundries.

In addition to their high performance qualities, SPC products typically require a simpler, more streamlined and cost-effective installation process than comparable WPC products. Their lightweight, slimline construction significantly reduces the time, labour, and resources required for installation, and can subsequently offer dramatic cost reductions.

HEARTRIDGE

Heartridge is the Australian leader in innovative, high performance flooring solutions that blend style and functionality. Heartridge is part of the Dunlop Flooring Group, a brand that has earned a national reputation for reliable, high quality flooring products. Taking a strong focus on delivering advanced, contemporary flooring solutions, Heartridge partners comprehensive technical knowledge with a genuine drive to progress the industry and deliver flooring solutions that represent the cutting edge in design, technology, and materials.

Heartridge products deliver realistic, high performing and durable alternatives to hardwood floors, and are backed by stringent end-to-end testing. All Heartridge products meet or exceed industry requirements for quality and performance, and come supplied with a lifetime structural guarantee.

HEARTRIDGE HYBRID VINYL PLANK

Heartridge Hybrid Vinyl Planks feature a rigid 3.5mm SPC core enclosed on both faces by a layer of luxury vinyl plank. The resulting structure and multi-layered composition delivers slimline planks with high dimensional stability that can resist impact, heavy weights and indentation.

This dimensional stability makes Heartridge Hybrid Vinyl Plank a top performer in even the most challenging conditions. Heartridge Hybrid Vinyl Plank can withstand direct heat and extreme cold with minimal expansion and contraction, and its ability to resist moisture allows spills to be easily mopped clean without the risk of warping or peeling.

The face layer of vinyl plank features a matte finish embossed in register surface for a natural and stylish timber appearance. An additional hardwearing layer of clear PVC increases the product’s scratch resistance, making it an ideal solution for high traffic areas. Whereas real timber requires ongoing maintenance to maintain its appealing, natural aesthetic, the rigid construction and composition of Heartridge Hybrid Vinyl Plank does away with the need for oiling, sanding or refinishing.

Heartridge Hybrid Vinyl Plank also promotes health and wellness in the home and in commercial areas. Thanks to its low VOC construction, Heartridge Hybrid Vinyl Plank can be safely installed in any indoor environment without reducing indoor environmental quality.

Heartridge Hybrid Vinyl Planks are acoustically tested, with results demonstrating a noise reduction result that falls underneath the performance requirements set by the National Construction Code. This quality makes Hybrid Vinyl Planks a perfect solution for apartments and multi-level homes. The planks can also be coupled with Dunlop Advantage 3, a rubber cork acoustic underlay that can boost already high acoustic insulation properties.

Reducing overall costs and labour, the integrated, user-friendly 5G-i locking mechanism used to install Heartridge Hybrid Vinyl Planks is simple and easy, and eliminates the need for adhesives. With a certified lifetime structural guarantee, designers and specifiers can choose Heartridge Hybrid Vinyl Plank with confidence.

1 Floor Covering News. “Scoring flooring: Industry stats for 2016.” FC News. https://fcnews.net/2017/07/scoring-flooring-industry-stats-for-2016 (accessed 13 August 2018).2 Moore, Lauren. “LVT drives resilient’s sharp growth.” Floor Covering Weekly. http://www.floorcoveringweekly.com/main/features/lvt-drives-resilients-sharp-growth-19402.aspx (accessed 13 August 2018).3 Clemens, Craig. “Woodfiber-plastic Composites in the United States - History and Current and Future Markets.” Forest Products Laboratory. https://www.fpl.fs.fed.us/documnts/pdf2000/clemo00b.pdf (accessed 13 August 2018).4 Floor Covering News. “Interview: Piet Dossche, the ‘father of WPC,’ mulls the evolving composite core landscape.” FC News. https://fcnews.net/2017/07/interview-piet-dossche-the-father-of-wpc-mulls-the-evolving-composite-core-landscape (accessed 13 August 2018).5 General Kinematics Corporation. “Wood Plastic Composite Uses and Benefits.” General Kinematics. https://www.generalkinematics.com/blog/wood-plastic-composite-uses-benefits (accessed 13 August 2018).6 Stone, Harlan. “LVT Evolution: What are the key differences between WPC and SPC?” Floor Daily. https://www.floordaily.net/floorfocus/lvt-evolution-what-are-the-key-differences-between-wpc-and-spc-dec-2017 (accessed 13 August 2018). 7 Migliore, Lew. “Luxury vinyl installation comes with unique challenges: Flooring Forensics.” Floor Daily. https://www.floordaily.net/floorfocus/luxury-vinyl-installation-comes-with-unique-challe (accessed 13 August 2018).8 Ibid.9 Ibid. 10 WFM. “Advantages and Disadvantages of WPC Boards.” Window & Facades Magazine. https://www.wfm.co.in/advantages-disadvantages-of-wpc-board (accessed 13 August 2018).11 Huang, Rhunzou, Yang Zhang, Xinwu Xu, Dingguo Zhuo and Qingling Wu. “Effect of Hybrid and Mineral Bamboo Fillers on Thermal Expansion Behaviour of Bamboo Fiber and Recycled Polypropylene-Polyethylene Composites.” BioResources. https://bioresources.cnr.ncsu.edu/BioRes_07/ BioRes_07_4_4563_Huang_ZXZW_Hybrid_Min_Bamboo_Expan_Plastic_Composite_2764.pdf (accessed 13 August 2018).12 Flooring Professionals. “Thermal Expansion of Luxury Vinyl Tile and Plank Flooring.” The Flooring Professionals. https://flooring-professionals.com/flooring-resources/thermal-expansion-luxury-vinyl-tile-plank-flooring (accessed 13 August 2018).13 Ibid. 14 Ibid.15 Above n 10.16 Building & Decor. “6 reasons to specify stone plastic composite.” Building & Decor. https://www.buildinganddecor.co.za/6-reasons-to-specify-stone-plastic-composite (accessed 13 August 2018).17 Above n 6.18 K2 Analytics. “Introducing Stone Plastic Composite Flooring (SPC).” Eco-Pro Planet. https://ecoproplanet.com/2017/10/21/introducing-stone-plastic-composite-flooring-spc (accessed 13 August 2018).19 Ibid.

REFERENCES

www.heartridge.com.au