How are vinyl floors constructed?

There are two main categories within vinyl flooring; Flexible and Rigid.

Flexible Vinyl
Flexible vinyl is commonly referred to as Luxury Vinyl Tile/Plank (LVT/LVP). This product type is formed through a mixture of polyvinyl chloride (PVC) with other materials to create a flexible finished product. Every Urban Surfaces’ product is made from first use raw materials. Only this way can the purity of the raw materials be ensured and the certainty of the avoidance of harmful additives or chemicals be known. Atop the waterproof PVC base is a high definition print film underneath a protective Wear Layer sheet. This “sandwich” is fused together and receives a factory embossing (texture). A final layer of high quality protective Polyurethane is applied to add to scratch resistant qualities to the surface.

Rigid Vinyl
Rigid vinyl flooring refers to products that have a sturdy, hardened base made of a PVC composite material. Urban Surfaces’ “Sound-Tec” and “SurfaceGuard” Floating Floor lines are made from a Stone Polymer Composite (SPC) core board. Our particular blend of rigid core flooring has 60%-70% Limestone mixed with PVC and other inputs. Limestone is hard, yet brittle in nature. PVC is introduced into a powdery, ground down limestone base to provide enough flexibility for the product to be formed correctly, yet remain rigid enough to hold its shape when installed over inconsistent surfaces.

A tongue and groove system is routed into the edges of the core material. Therefore, the core material needs to have a high level of strength to withstand constant foot falls and other forces pressing down upon it.

The construction of the material continues with a print film atop the SPC core safely protected by a wear layer sheet above. These 3 layers are fuzed together under high extreme and pressure to permanently bond the layers into a single lamination. This process produces a product that virtually eliminates delamination common in other rigid vinyl flooring types. Other rigid core vinyl flooring products, such as WPC are not heat fuzed but rather cold pressed. This system relies on a glue layer between the upper and lower layers to hold the entire piece together. This glue layer breaks down over time when subjected to high traffic causing a delamination failure.

Atop the wear layer, a flood coat of Polyurethane is applied to complete the factory finish. Polyurethane surfaces are scratch and stain resistant and are easy to clean and maintain.

Underneath the SPC core, a factory applied pad is pre-attached. This eliminates the need for underlayments to be rolled out and installed on the job site while adding comfort underfoot. The pad acts as a sound blocker between levels when installed in upper levels.

Click here for fully transparent sound test reports performed by third party testing labs.