The Instructions Usually Decide It
Manufacturers publish installation instructions because their products depend on them. Flooring, doors, windows, drywall, adhesives, sealants, cabinets and finish products all come with requirements for substrate, environment, fastening, spacing and sequence. Specifications and building codes frequently require installation in accordance with those instructions, and warranties often depend on it.
When an installation is challenged, the first question Paul asks is: what did the instructions require for this product on the date it was installed? Instructions are revised over time, so he looks for the version that applied, using product data, submittals, packaging and manufacturer archives where available.
Elements of Installation Paul Examines
- Substrate. Flatness, cleanliness, moisture condition and readiness to receive the product
- Environment. Temperature, humidity and acclimation requirements at the time of installation
- Fastening and adhesion. Type, spacing, pattern and coverage of fasteners or adhesive
- Clearances. Expansion gaps, reveals and tolerances around the installed product
- Accessories. Trim, transitions, flashings, sealants and hardware called for by the system
- Sequence. Whether the product was installed at the right point in the overall work
Specifications and Approved Submittals
On commercial projects and many custom residential projects, the specifications add requirements beyond the manufacturer's instructions, and approved submittals record which products and details were accepted. Paul reviews them together. An installation can follow the manufacturer's instructions and still depart from the specification, or follow an approved submittal that differs from the original drawings. Those distinctions often determine responsibility.
When Instructions and Field Conditions Conflict
Sometimes field conditions make the instructions difficult to follow: an uneven existing floor, an out-of-plumb opening, a schedule that left no time for acclimation. A competent installer identifies those conditions and raises them before proceeding. Paul looks for evidence that the conflict was recognized and communicated, through RFIs, emails or daily reports. Proceeding without addressing a known condition is a different situation from encountering a concealed one.
Typical Improper Installation Matters
Paul's improper installation work commonly involves flooring systems, doors and hardware, cabinets and millwork, drywall and interior partitions, and fixtures and accessories. Where an installation question requires engineering analysis, such as structural attachment design or mechanical system performance, he limits his opinion to the observable installation and identifies the need for the appropriate engineer. Related pages: defective carpentry and finishes and poor construction workmanship.