The flooring industry has seen rapid growth recently in segments like luxury vinyl tile (LVT) and luxury vinyl plank (LVP). Resilient flooring, in which the wear surface is non-textile, non-wood and non-stone, has been the leading growth segment in the industry for the past two decades, experiencing significant growth and capturing the second-largest share of the floor covering market in 2023. LVT alone represents 27.6 percent of manufacturers' sales.
The increasing popularity of vinyl flooring as the go-to choice for home renovation is driven by the growing desire to modernize living spaces with easy-to-use materials. Through the adoption of advanced production techniques, vinyl flooring now offers enhanced performance, design, and installation, resulting in superior resolutions and sharper textures.
However, with this growth comes new challenges, particularly in installation and product performance. BASF has emerged as a leader in providing sustainable, high-performing adhesives tailored to meet these demands. With a focus on environmental responsibility and innovation, BASF is addressing the critical needs of formulators and installers alike.
BASF's flooring adhesives stand out for their commitment to sustainability. The company has developed products free from red-listed ingredients such as Alkylphenol Ethoxylates (APEOs) and other harmful surfactants, aligning with green building programs like Cradle to Cradle (C2C) and the Living Building Challenge. This shift reflects an industry-wide move toward sustainability, where the removal of ingredients of concern not only benefits the environment but also contributes to healthier indoor air quality, earning certifications like Green Label Plus and FloorScore.
"We’ve worked hard to eliminate red-listed ingredients without compromising performance. Our adhesives now meet stringent green building program requirements while maintaining industry-leading standards," said Chris Hummel, BASF Market Segment Manager.
One of the biggest challenges in modern flooring installations is speed, particularly when dealing with high moisture and high alkalinity in concrete substrates. As construction schedules tighten, installers need adhesives that can handle rapid installations over green concrete, substrates with high moisture content, and varying substrate types, including low-energy surfaces. BASF's product portfolio addresses these challenges with solutions like Acronal® A 280, Acronal 3633 and Acronal 4810.
Acronal A 280: A high-solids latex designed to minimize water in formulations, ideal for substrates with low energy and quick dry requirements. The product also offers a balance of peel and shear performance.
Acronal 3633: A quick-drying adhesive engineered for use on low-energy substrates, offering excellent peel and tack performance in fast-paced installations.
Acronal 4810: Specifically designed to resist plasticizer migration, a common issue in heavily plasticized materials like luxury vinyl planks, ensuring long-term adhesive flexibility and strength.Contact BASF for questions relating to its portfolio of sustainable flooring adhesives.
"Speed of installation is a priority for our customers. We’ve developed products like Acronal 3633 with a quick-dry feature, allowing installers to work faster without sacrificing bond strength," said Randall Petrie, BASF Senior Technical Specialist. Moisture content and pH levels of concrete floors present significant challenges for installers.
BASF's adhesives are formulated to perform under high moisture and high pH conditions, with some products capable of withstanding relative humidity levels as high as 99% and pH levels up to 12. "High moisture content in concrete is a common problem in fast-track installations. Our adhesives are engineered to withstand extreme conditions, making sure the bond holds even in high humidity or pH environments," Hummel added. Another approach to high alkali moisture content in concrete is to utilize a primer. Styrofan 4104 and Acronal 4312 provide strong barriers, ensuring that adhesives maintain their integrity even in demanding environments.
Flooring adhesives must accommodate a variety of application techniques. BASF's formulations are engineered for both wet-set and pressure-sensitive adhesive (PSA) applications, each offering unique benefits:
Pressure-Sensitive Adhesives: Products like Acronal 3633 offer a high tack and peel performance, essential for non-porous substrates where the adhesive needs to "flash off" the water before bonding. These adhesives offer a long working time—up to 24 hours—giving installers flexibility during the installation process.
Wet-Set Adhesives: Wet-set adhesives, by contrast, form a stronger bond by allowing the flooring to be laid while water is still present in the adhesive. This method, although slower, provides a more robust bond, particularly for substrates where speed is less critical. "Our pressure-sensitive adhesives give installers more time and flexibility. Acronal 3633, for instance, allows them to lay flooring up to 24 hours after application, offering excellent bond strength," noted Petrie.
As flooring materials continue to evolve, so do the challenges installers face. Innovations in luxury vinyl tile and plank have led to dimensional stability issues, such as shrinkage and gap formation due to temperature fluctuations. BASF’s adhesives help mitigate these concerns by offering high-shear performing polymers that maintain bond strength without compromising dimensional stability. Additionally, products are being developed to better bond to newer, more hydrophobic substrates, addressing the shift away from traditional plasticizer-heavy materials to more environmentally friendly alternatives like polyolefins. "We’re seeing a lot of movement in the market toward low-energy substrates, which are more environmentally friendly but harder to bond to. Our customers are looking for polymers that can handle this, and we’re delivering," Hummel said.
In summary, BASF has revolutionized its flooring adhesive product line to meet the growing demands of sustainability and performance. From eliminating red-listed ingredients to developing adhesives that can withstand high moisture and pH levels, BASF provides formulators and installers with solutions that ensure durability, flexibility, and ease of use. Whether addressing plasticizer migration, bonding to low-energy substrates, or enabling fast-paced installations, BASF’s products are leading the way in the next generation of flooring adhesives. "Our goal is to continually innovate and offer solutions that not only meet today's demands but also anticipate the future needs of the industry. We’re proud to support our customers with products that align with sustainability goals while providing the performance they expect," concluded Petrie.
Contact BASF for questions relating to its portfolio of sustainable flooring adhesives.