Vinyl Plank Flooring: A Professional’s Guide to Understanding Its Challenges and Implications

Vinyl plank flooring has emerged as a dominant choice in the flooring market over the last decade. It’s widely advertised as waterproof, durable, and easy to install, making it appealing for both residential and commercial spaces. But beneath the marketing claims lies a more complex story—one that professionals in the insurance and contracting industries need to understand.

To unpack this, let’s explore the evolution of vinyl plank flooring, the technical challenges it presents, and its implications for adjusters and contractors.

The Early Days: WPC Flooring Enters the Market

In the mid-2000s, I encountered vinyl composite plank flooring for the first time with a product called Coretec, introduced by U.S. Floors. This was the first wood-plastic composite (WPC) product of its kind I had seen. At the time, luxury vinyl plank (LVP) existed but wasn’t taken seriously—it was mostly ignored in showrooms.

Coretec, however, stood out. It was thicker, sturdier, and more realistic in appearance compared to other vinyl options, which often looked cheap. I installed Coretec in a Newport Beach home with a raised foundation and a wood subfloor over a crawl space on the sand. The homeowner needed something durable to handle wet, sandy feet coming straight off the beach, and Coretec performed well in that environment.

Despite its potential, Coretec and similar products didn’t initially gain much traction in our showroom. It wasn’t until competitors started flooding the market five to seven years later that WPC products began to gain attention.

The Rise of Vinyl Plank Flooring: Solving Laminate’s Failures

One of the key factors driving the rise of vinyl plank flooring were problems with laminate flooring. When laminate was first introduced in the 1990s, brands like Pergo and Wilsonart produced high-quality high-pressure laminate (HPL) products. These were durable, scratch-resistant, and designed to last.

However, the market was soon flooded with cheaper direct-press laminate (DPL) alternatives, including low-quality imports. Many of these products were thicker—often 12mm compared to the denser, higher-quality 8mm European and American laminates—but performed poorly. They scratched easily, handled spills poorly, and were highly susceptible to water damage. Consumers were left frustrated, and laminate flooring’s reputation suffered. Additionally, the higher quality HPL laminates did not have the newer hardwood looks such as textured surfaces and in-register embossing, so the cheaper direct-press laminate products looked better in the showroom.

Vinyl composite plank flooring entered the scene as the solution. Its “waterproof” branding addressed one of laminate’s biggest weaknesses. However, as WPC became more widely adopted, issues with the product began to surface.

Understanding WPC and Its Limitations

WPC was revolutionary but far from perfect. One of the biggest challenges was its tendency to expand and contract with temperature fluctuations. This made it problematic in large spaces or areas exposed to significant sunlight.

For example, a major manufacturer once sent sales representatives to our showroom to recommend gluing down their WPC products in front of large windows exposed to direct sunlight. This advice directly contradicted industry standards for floating floors, highlighting how manufacturers were struggling to address these early problems.

SPC Flooring: The New Front-Runner with Its Own Set of Problems

Stone-plastic composite (SPC) flooring, the next evolution in vinyl plank technology, was introduced as a denser, more durable alternative to WPC. While it solved some of WPC’s issues, SPC came with its own challenges.

Moisture Vapor Emissions and Trapped Water

One of the most significant issues with SPC flooring is its lack of permeability. In my experience, SPC is even less permeable than many moisture vapor retarders, such as 6-mil polyethylene sheeting or epoxy coatings over concrete. While these retarders slow the transfer of moisture vapor from the slab, SPC flooring can trap any moisture that does escape, leading to a net buildup over time. This buildup eventually causes cupping, dimensional changes, microbial growth, and attached underlayment failure.

Water also becomes trapped beneath SPC flooring due to spills or flooding, and any water that seeps beneath the planks is nearly impossible to dry without full removal, further compounding the problem.

The Dangers of Installing Over Existing Floors

An increasingly common problem with vinyl plank flooring is improper installation over existing flooring. Many manufacturers’ installation instructions are ambiguous, or even misleading, on this issue.

In my experience, most instructions do not clearly state that it’s crucial to remove hardwood flooring installed over on-grade concrete. In fact, many guidelines explicitly allow installation over hardwood, but fail to specify the conditions under which this is acceptable. The fine print often includes moisture testing requirements for the concrete slab—testing that is impossible to perform if the existing flooring is not removed.

This ambiguity has resulted in significant issues. For example, installing vinyl plank flooring over existing tile or hardwood can trap moisture underneath. Trapped groundwater vapor emissions will lead to swelling, cupping, and eventual failure of the floor.

During the real estate boom of the 2010s and 2020s, home flippers often installed vinyl plank flooring over old, abandoned hardwood or tile to save time and costs. Buyers of these homes were frequently unaware of the improper installation. The floors often failed shortly after purchase, leaving homeowners to deal with the consequences—groundwater-related damage not covered by insurance and disputes with contractors over liability.

Challenges for Insurance Adjusters and Contractors

Vinyl plank flooring presents unique challenges in insurance claims, particularly when trying to distinguish between pre-existing damage and loss-related damage:

1. Identifying Damage

The dense construction of SPC can mask moisture issues until significant damage has occurred.

Groundwater vapor or other types of water exposure can cause cumulative damage over time, making it difficult to determine liability in a loss scenario.

2. Repair Limitations

Cupped or warped planks cannot be replaced seamlessly with new flat planks, as this compromises the locking systems.

Continuous flooring installations often force contractors to remove unaffected sections, leading to higher costs and potential disputes with insurers.

3. Warranty Complications

Many manufacturers set unattainable standards for moisture testing, effectively voiding most warranties.

Changes to installation guidelines often shift the burden of proof onto contractors, leaving them vulnerable to accusations of improper installation—even if they followed the guidelines available at the time.

As a flooring inspector, I am often called to investigate failed vinyl plank floors where no water loss has occurred. In nearly every case, the failure is due to trapped groundwater moisture vapor emissions. Insurance companies typically deny these claims, leaving homeowners to negotiate with contractors over who should cover the costs.

Practical Recommendations for Homeowners

If you’re considering vinyl plank flooring, especially SPC, follow these steps to protect yourself:

Save Documentation: Keep a copy of the manufacturer’s installation instructions and warranty. Ensure your contractor follows these precisely, and retain the documents in case they change later.

Moisture Testing: If a concrete slab does not meet the manufacturer’s requirements for moisture vapor emissions or moisture content, choose a different flooring product. Do not rely solely on moisture retarders, as they may not solve the issue.

Verify Moisture Limits in Writing: If a manufacturer recommends a moisture vapor retarder like 6-mil polyethylene sheeting, ask them to provide the exact moisture limitations in writing. If they refuse, reconsider using their product.

These precautions can save homeowners from costly disputes and failed floors. For contractors, following these steps ensures you avoid liability for improper installations.

The Bottom Line: Proceed with Caution

Vinyl plank flooring, particularly SPC, has transformed the flooring market with its affordability and convenience. However, it’s not without its challenges, especially in environments prone to moisture or temperature fluctuations. For insurance adjusters and contractors, understanding these products’ limitations is essential.

Over nearly two decades of conducting flooring inspections in Southern California and performing countless concrete moisture vapor emissions tests, I can confidently state that it is rare for a concrete slab in this region to meet the moisture emission limits set by vinyl plank flooring manufacturers. Despite this, these products are sold daily without manufacturers being transparent with consumers about the critical need to ensure their concrete slabs are suitable for installation. If manufacturers were transparent about their products’ concrete moisture limitations and warranty requirements, it is likely their products would attract few buyers.

Furthermore, I have not encountered any vinyl plank flooring installation instructions or warranties that clearly specify acceptable concrete moisture limits when a recommended 6-mil poly moisture vapor retarder is used. I’ve been told: “just use 6 mil poly, you’ll have no problems.”

Many, if not most, of these manufacturers also recommend specific underlayments for use with their products. However, as with vinyl plank flooring itself, very few concrete slabs in Southern California fall below the maximum moisture limits specified for these moisture vapor retarding underlayments.

Unfortunately, these products are sold to consumers who are often unaware of the potential issues. When problems arise, they frequently discover that their warranty is void, leaving them without recourse.

Caveat Emptor

At the end of the day, vinyl plank flooring may be a valuable option—but only when installed under the right conditions and with realistic expectations about its performance.

Dave Fitzpatrick is a licensed C15 and C54 flooring inspector who provides opinions for the property liability industry.