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Vinyl Flooring : How It Is Made And Manufactured

A look in today’s homes show that vinyl is an extremely popular choice amongst homeowners for flooring purposes in virtually every room.

But one may wonder how this wonderful choice for flooring is manufactured to provide style, damage-resistance, and waterproof properties. We invite you to read on and learn how vinyl flooring is made. With a better understanding, perhaps you will also be persuaded to decorate your home with one of society’s favourite flooring material.

The production for sheet vinyl uses highly sophisticated techniques, complex methods and precise systems to provide you and your home with beautiful, high-quality and high-performing floors. Recent advances in its manufacturing process can offer even more beautiful, durable and stylish choices.

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Ingredients and process

The foundational element in this type of flooring is polyvinyl chloride (PVC) resin created from plastic pellets, with additional compounds that modify the qualities of the resulting material. These additives include stabilizers, plasticizers, pigments, and fillers. Some vinyl floors can also include antimicrobial elements to prevent the growth of mould and bacteria. Stabilizers help to preserve the vinyl and minimize fading over time due to heat and light. Plasticizers modify the texture to create softer and more flexible material. Pigments are added to give the flooring its colour, and fillers can also help in creating specific design aesthetics. Additionally, fillers extend the PVC resin. In order for PVC pellets to be transformed from individual pieces of plastic into beautiful vinyl flooring, extraordinary heat and pressure are used to melt them down to a smooth consistency. This substance is then blended with the additives above according to the desired qualities of the end product.

Options : sheets, tiles, and planks

For sheet vinyl, the liquid plastic is spread in a very thin layer onto the backing, then dried with hot air. As the liquid dries, it fuses with the back to produce an extremely durable sheet. These sheets are available in wide rolls that can be cut to size. Vinyl tiles are manufactured similarly to sheet vinyl, but they are cut in 6-, 9-, or 12-inch squares and often designed with patterns that imitate natural stone. These tiles are usually installed with the peel-and-stick method, resulting in a smooth and uniform appearance, not to mention how easy they are to “DIY. Inlay vinyl tiles are created by fusing multiple layers of the same colour. This method produces a remarkably resilient option, since each layer appears the same as the first, meaning wear does not show over time.

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The rotogravure printing process produces vinyl flooring of unlimited designs

The rotogravure process is a printing technique that is commonly used for making vinyl floors. It has the capability to produce vinyl with unlimited possibilities in pattern, colour, texture and design. The rotogravure process uses a print cylinder that spins while the vinyl’s core layer passes underneath for printing of various ink dyes that create a pattern. Once the dyes are set, a clear protective wear layer is applied to the surface of the flooring.

The performance of the vinyl product is highly-dependent on the protective wear layer, making it a critical component

The thickness of the wear layer is the true determinant and it can vary between vinyl collection or series. It is measured in mils, which is about the same thickness as a page in the telephone book. So, a 10-mil wear layer is comparable to approximately 10 pages from the telephone book.  The general rule of thumb is that more expensive and higher-quality of vinyl will have thicker protective wear layers that boost durability and damage-resistance. Having a strong protective wear layer will also help you maintain long-lasting aesthetics of new and attractive vinyl flooring. Additionally, this layer plays a role in other performance characteristics that are key to vinyl such as: easy maintenance, stain resistance, scratch resistance and waterproof.

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The easy maintenance necessary to maintain the aesthetic of vinyl flooring is simple but important

When flooring begins to look worn and drab, it is often caused by the thousands of fine scratches in the protective wear layer. These scratch lines capture dirt, grit and sand that further lead to damages. Fortunately, Vinyl flooring protective wear layers are incredibly strong and durable, so they can resist showing any wear and stains. This is partly why vinyl flooring has risen in popularity as one of the top choices for homeowners who want practical, beautiful flooring options. 

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