Installation Information

Crosstrack Installation Instructions

The unique solidity of the Crosstrack flooring results from its continuously supporting cellular structure which is bedded onto high build adhesive. Correct installation procedures are therefore of vital importance.

• Preparation
• Levelling
• Set out
• Laying
• Fitting to edges
• Curing time
• Protection
• Other handy tips

1. Remove all loose materials from base floor.
2. Remove all lumps (plaster, concrete, etc) and dress to clean flat surface.
3. Seal and prime areas affected by oil or grease.
4. Fill heavily damaged or pitted areas.
5. Vacuum the area immediately prior to laying.

Whilst the finished Crosstrack floor can be closer to level than the original sub-floor, it will generally follow existing contours.

Minor levelling

Minor levelling is achieved by using the high build glue or adhesive.

For additional levelling

(maximum approx 5 - 7mm over 1.2 - 1.8 m)

1. Place the Crosstrack 4mm shims under two of the free corners of the installed module. Place this module on floor without prior applying of adhesive.
2. Insert adhesive under pillars by placing nozzle of applicator in the slot of the shim.
3. Apply required amount of adhesive.
4. After the floor level has been achieved and adhesive has set, lift deck from base. Note one at a time as it is not recommended that installs walk on unsupported base only.
5. Place shims under central and edge base pillars and apply glue as before.
6. Fix deck back onto base.
7. Ensure that adhesive is cured before accessing those areas.

Major levelling

Badly uneven floors should be filled with a self levelling compound.

1. Ensure that the Crosstrack channels align closely with the respective service entry and exit point.
2. Ensure that the upper channels are laid in the direction of the main cable routes. if in doubt consult with either builder or electrical trades.
3. To minimise any cutting and waste try to start the laying closest to the corner.
4. Mark the starting lines, at right angles of each other, closest to this corner and the walls.
5. Start laying from this point.
6. It is unwise to start laying modules directly against the wall as wells might not be straight.

Generally the Crosstrack modules are packed with the deck facing down. Transfer modules to the laying are in a similar way as this will make it easier to apply adhesive to underside of base pillars.

1. Adhesive, approximately the size of a walnut, should be applied to the underside each of the 16 base pillars.
2. Turn the module around and locate in correct laying position. Note correct orientation of service channels marked on deck.
3. Slide module into interlocking fit with the already installed adjoining modules.
4. Do not walk onto installed modules until an area of 6 - 12 modules has been laid.
5. Once 6 - 12 modules has been installed, level the floor by applying pressure on the high spots of the installed floor. use a straight edge to check flatness.

Edge modules should be cut and fitted only when the main part of the floor has been installed and the glue is cured.

Marking of the edge module for cutting

1. Place the module to be cut exactly over the module adjacent the edge, with the deck side up.
2. Place an additional module with deck side down on to this module.
3. Align latter module with the wall and mark the cutting edge on the to be cut module.
4. Cut the module using a sharp saw. Be careful of screws.

Generally the floor will withstand light foot traffic 24 hours after laying. This will be longer when glue is applied in cold water or in poorly ventilated areas or on impervious laying base surfaces.

Two weeks is required for full curing of the adhesive.

When and if floor finished such as carpet or vinyl is not laid immediately after the Crosstrack floor is installed it is important that the floor is protected. heavy duty plastic sheets or others should be laid over the entire floor area and turned up against the walls.

• Prior to starting work on site request a clear, unrestricted and direct access route to the installation areas. Especially if each and every tile will need to be carried to this area.
• It is important that a proper undercover storage area is requested prior to delivering goods to site.
• Have any completed installation inspected by appropriate representative of the customer prior to leaving site. Have all defects listed in writing.
• Make sure that no other personnel other than those with authority, access the installation area during installation and for 24 hours after completion.