1、 The floor cannot be locked or the lock buckle is disengaged
Phenomenon: During installation, the male buckle cannot be fully inserted into the female buckle slot, or after installation, the edge of the floor can be gently lifted by hand to separate. When struck, it produces a hollow "pa pa" sound instead of a solid "dong dong" sound.
Root cause analysis:
There are debris, sand particles or packaging residues in the locking groove
Not using the correct tilt angle during installation (should be inserted at 30 ° -45 °)
The lock buckle itself has manufacturing tolerances (male buckle too large or female buckle too shallow)
Polypropylene becomes brittle in low temperature environments, and the elastic arm cannot deform and bite normally
Processing method:
Suspend installation, clean the locking groove with high-pressure air or a hard brush, and especially clean the dead corners at the crossroads
If it is caused by low temperature (ambient temperature below 10 ℃), use a hot air gun to adjust the temperature to 80-100 ℃ and sweep along the edge of the lock at a suitable speed (20cm distance, not allowed to stay), heat and soften before pressing
Check the size of the lock buckle: Use a vernier caliper to measure the thickness of the male buckle (standard should be 1.8-2.2mm) and the size of the female buckle groove (should be 0.3-0.5mm deeper than the thickness of the male buckle). Batches that exceed the tolerance range should be replaced
Temporary emergency response: Apply a small amount of paraffin wax on the surface of the male buckle (oil cannot be used as it will accelerate the aging of the rubber seal ring) to reduce insertion resistance
Preventive measures: After unpacking, knock the floor upright and shake off packaging debris; Store flooring materials indoors (15-25 ℃) for at least 24 hours before winter construction.
2、 Local arching or wavy shapes appear after paving
Phenomenon: The floor surface is uneven, with obvious undulations when stepping on it, or the middle area of the site bulges to form a "hump". In severe cases, there may be a height difference of more than 2mm between adjacent floors.
Root cause analysis:
The flatness of the foundation ground exceeds the standard (the height difference measured with a 2-meter ruler exceeds 3mm)
During installation, no expansion joints were reserved or the surrounding area was blocked
Installed in high temperature weather, insufficient space for thermal expansion and contraction leads to compression and arching
The floor itself is warped and deformed (caused by improper packaging and storage)
Processing method:
Confirm if it is caused by thermal expansion: Measure the surface temperature of the floor (infrared thermometer). If it exceeds 50 ℃ and there are no gaps around, remove it from the edge, use a cutting machine to narrow the surrounding floor by 5-10mm, and reinstall it
If the foundation is uneven: remove the floor in the arched area, use an angle grinder to polish the high points (the parts where the concrete is higher) or fill the low-lying areas with self leveling (use epoxy mortar for areas below 2mm and cement self leveling for areas above 2mm). After leveling, lay it again
Floor warping: Place the warped board flat on a flat surface, apply a weight (not less than 50kg per square meter) above it, heat the surface evenly with a hot air gun to 60-70 ℃, and maintain the pressure to cool to room temperature to correct most of the warping
Preventive measures: Before installation, it is necessary to use a 2-meter ruler and a feeler gauge to check the flatness of the foundation point by point; 10-15mm expansion joints shall be reserved around and temporarily filled with wooden battens; Construction should be carried out in the morning and evening hours during high temperature weather (>35 ℃).
3、 Edge curling or cutting edge fragmentation
Phenomenon: The edge of the floor at the edge of the edge strip around the venue is significantly raised, and it shakes up and down when stepping on it. The edges after cutting appear jagged or small pieces fall off.
Root cause analysis:
The edge strip is not firmly fixed or the spacing is too large (more than 50cm without expansion bolts)
Improper use of tools during cutting (insufficient number of cuts or excessive force from the art knife)
Ground subsidence or warping at the edge of the foundation
Cutting at low temperatures leads to brittle edge breakage
Processing method:
Reinforcement of edge strip: Remove the original edge strip, drill new holes (with a diameter 2mm larger than the expansion bolt), and increase the bolt spacing to 30-35cm. Install a 3mm thick rubber gasket between the edge strip and the floor, and after compression, the edge should be fully attached to the foundation ground
Attentive service for cutting edge: Use a fine toothed curved saw (tooth pitch ≤ 2mm) to re cut along the original cutting line, and feed from the front of the floor during cutting. If the edge breakage is severe, cut off the damaged part and replace it with a new board
Foundation edge sinking: Inject epoxy resin (syringe injection) below this area, level it after curing, and reinstall the edge plate
Preventive measures: Leave the floor at room temperature for at least 4 hours before cutting; Use a mountain (ruler or angle steel) to guide during cutting; The spacing between edge bolts should be strictly controlled within 40cm, and the distance from the edge of the floor should not exceed 5cm.
4、 Stepping noise (creaking or popping sound)
Phenomenon: Continuous noise from the floor during walking or dribbling, usually occurring in fixed areas rather than the entire field.
Root cause analysis:
The lock buckle is not fully in place, there is a small gap, and they rub against each other when subjected to force
There are small protrusions on the foundation ground (such as cement lumps), and the floor bounces under pressure after being elevated
There are loose particles between the bottom of the floor and the foundation
The support pillar broke and the floor partially collapsed, coming into contact with the foundation
Processing method:
Locate the source of the abnormal noise: One person steps slowly, while the other person bends down and uses a stethoscope or a long screwdriver to press against the floor surface (with the other end attached to the ear), accurately identifying the source of the abnormal noise
Lock gap: Mark in the area of abnormal noise, remove and reinstall, apply paraffin wax to the lock buckle during installation, and evenly tap with a rubber hammer (from the center to the periphery)
Foundation protrusion: Remove the floor, grind the protrusion with an angle grinder until it is flat, clean the debris, and then lay it again
Pillar fracture: After dismantling, check the fractured pillar. If it is a local minority (
Preventive measures: Thoroughly clean the foundation floor with an industrial vacuum cleaner before installation; After laying each row, use a rubber hammer to strike all locking positions to confirm they are in place; Within 24 hours after installation, avoid heavy objects from crushing and allow the floor to naturally release stress.
5、 Water accumulation or poor drainage (outdoor area)
Phenomenon: Local water accumulation on the surface of the site after rain has not been drained for more than 30 minutes, or the water remains in the hollow grid and cannot infiltrate.
Root cause analysis:
Insufficient or reverse slope of the foundation ground (should have a drainage slope of 0.3% -0.5%)
The floor hollowing rate is too low (
The bottom of the floor is blocked by dust and leaves, and the drainage channel is obstructed
Incorrect floor orientation during installation (drainage channel not aligned with slope direction)
Processing method:
Check the basic slope: Measure with a level or a long level ruler. If the slope is less than 0.2%, a new leveling layer (not less than 30mm fine aggregate concrete at the thin part) needs to be made
Clearing blockages: Use a high-pressure water gun (pressure ≤ 5MPa, to avoid damaging the lock buckle) to flush from high to low on the site and clear the bottom channel. Stubborn blockage can be blown back with compressed air
Direction adjustment: Some floors are designed with one-way drainage channels. Check the back of the floor, the direction of the drainage channel should be consistent with the slope direction. If installed in reverse, it needs to be dismantled and re laid (rotated 90 °)
Temporary drainage: Use an electric drill to drill auxiliary drainage holes with a diameter of 5mm in areas with severe water accumulation (3-5 holes per board), avoiding the position of supporting pillars
Preventive measures: Before installation, sprinkle water on the foundation ground, observe the direction of water flow, and confirm the drainage path; Clean the site with a high-pressure water gun every six months.
6、 Color difference or uneven fading
Phenomenon: There are significant differences in color depth within the same site, or after several months of use, some areas have noticeably lighter colors than others (fading patches).
Root cause analysis:
Different batches of color masterbatch have regional differences, especially in the red and blue series
Inconsistent orientation of the floor during installation (directional injection flow marks on the back)
Local areas are strongly exposed to ultraviolet radiation (such as reflected light near glass curtain walls)
Surface fading caused by the use of chemical cleaning agents (such as strong alkali, solvents)
Processing method:
Batch color difference: unable to provide attentive on-site service. If the difference is unacceptable, it needs to be replaced with the same batch of flooring. When purchasing, the supplier is required to provide products with the same production batch number and reserve 5% spare boards
Orientation issue: Check the position of the injection molding points on the back of the floor and confirm that all floor installation directions are consistent (injection molding points point to the same side). If there is inconsistency, dismantle and adjust
Reflected light fading: Install sunshade nets or UV resistant films on glass curtain walls or metal reflective surfaces. The faded area cannot be restored and can only be replaced
Cleaning agent damage: Do not use strong alkalis (such as NaOH) or aromatic solvents (such as toluene) for cleaning. Faded areas can be sprayed with PP one on one color paste for attentive service (requires focused construction)
Preventive measures: When purchasing in bulk, it is required that the color difference value Δ E be less than or equal to; 1.5； Classify by color code before installation; Use neutral cleaning agents (pH 6-8) and a soft bristled brush for daily cleaning.
7、 Local subsidence or depression
Phenomenon: After using for a period of time, specific areas of the court (such as the basketball three second zone and the front serving line of badminton) show obvious indentations, the foot feel becomes softer, and the ball does not bounce back when it lands.
Root cause analysis:
The foundation ground has local hollowing or loose layers in this area
Long term impact leads to creep of supporting pillars (material fatigue)
The foundation under the floor is softened by soaking in water (such as poor drainage in outdoor areas)
Insufficient thickness of flooring (
Processing method:
Reason for judgment: If there is a hollow drum sound (similar to hitting an empty can) when tapping on the floor of a recessed area, it is considered a basic hollow drum; If there is no empty drum sound but the floor becomes noticeably soft, it is due to pillar fatigue
Basic hollowing: Remove the floor, chisel out the hollowing layer to a solid base, repair with high-strength epoxy mortar, and re lay after 7 days of curing
Pillar fatigue: Replace with encrypted pillar type flooring (reduce pillar spacing by 15%), or install an elastic cushion layer (3mm EVA sheet) below the original position
Basic soaking: Check the drainage system, provide attentive service, air dry the foundation (moisture content ≤ 5%), and replace the deformed floor
Preventive measures: Before installation, use a hollow drum hammer to fully inspect the foundation ground; Select flooring with a thickness of ≥ 16mm for high-intensity sports areas (basketball, volleyball); Confirm that the drainage slope of the outdoor site is ≥ 0.5%.
8、 Excessive gap or compression deformation caused by thermal expansion and contraction
Phenomenon: In winter, there are obvious gaps (>3mm) around the site, or in summer, there are small bulges in the middle of the site at the arch and lock buckle.
Root cause analysis:
Insufficient reserved expansion joints (should be 10-15mm, but only 5mm was actually left)
Expansion joints are filled with cement and debris
Extreme temperature difference (such as -15 ℃ in winter to 40 ℃ in summer) exceeds the design range
The coefficient of linear expansion of the floor is too large (>10 × 10 ⁻⁵/℃)
Processing method:
Excessive gaps in winter: Use a one-to-one filling strip (TPE material, width 8-12mm) to press into the gap, which can expand and contract with temperature changes. Cannot be filled with cement or glass glue
Summer arching: Immediately cut a 5mm wide expansion joint in the arching area (using a cutting machine, with dimensions penetrating the floor) to release stress. Install a one-to-one expansion joint cover strip after cooling down
Lock buckle drum: Use a rubber hammer to strike from the drum in all directions. If it cannot be removed, remove the area and cut each board to a narrow 2mm before reinstalling
Preventive measures: during installation, the width of the expansion joint is calculated (L ×α×Δ T × 1.5, L is the length of the site, α is the linear expansion coefficient, Δ T is the annual temperature difference, and 1.5 is the Enron coefficient), and the length of 10m is generally at least 12mm; the expansion joint is filled with flexible materials (closed cell foam strips) to prevent sundries from entering.
Summary in one sentence: 90% of installation problems are caused by insufficient flatness of the foundation and improper reservation of expansion joints, and half of the remaining 10% are due to the lock buckle not being knocked in place. Spending an extra 10 minutes inspecting the foundation, compacting each board, and leaving enough wall seams during installation can avoid 80% of maintenance troubles in the future.
