How To Remove a Vinyl Floor and Plywood Subfloor

Removing an old vinyl floor and plywood subfloor can reveal hidden treasures beneath, such as beautiful hardwood flooring. This process requires some effort but can dramatically transform your space. In this guide, we’ll walk you through how to remove your vinyl floor and subfloor without damaging what’s underneath. This Old House general contractor Tom Silva demonstrates this process in the video above.

Assessing the Floor Before Removing the Vinyl Floor

First, assess your current flooring situation to determine the best approach and prepare for any challenges you might encounter.

Identifying the Flooring Layers

Start by examining the edges of your floor—particularly near thresholds or where the flooring meets the wall. You may be able to see these different layers:

• Vinyl flooring (top layer)
• Plywood subfloor (middle layer)
• Original flooring (bottom layer, potentially hardwood)

Checking for Hazardous Materials

Older vinyl flooring and adhesives may contain asbestos, which is a hazardous material. If your home was built before 1980, we recommend having the flooring tested for asbestos. If asbestos is present, you’ll need to hire a professional abatement company to remove it safely.

Gathering Tools and Materials To Remove a Subfloor and Floor

Having the right tools on hand will make the job much easier and more efficient. Here’s a list of items you’ll need:

• Detail sander
• Flat pry bar
• Impact driver
• Long-handled floor scraper
• Oscillating multi-tool
• Respirator
• Safety glasses
• Wet/dry vacuum
• Wide putty knife
• Wood chisel
• Work gloves

Removing the Vinyl Flooring

With your tools gathered and assessment complete, you can start removing the vinyl flooring. 

Starting at the Edge

Begin at a threshold or corner of the room. Use a wood chisel and a wide, stiff-blade putty knife to pry up the edge of a vinyl tile. This technique allows you to assess the condition of the plywood underlayment beneath the tiles.

Scraping Up the Tiles

Once you’ve loosened an edge, use a flat pry bar and long-handled floor scraper to remove the rest of the vinyl tiles. Work across the room, being careful not to gouge the plywood underneath. Different tools may work better depending on the adhesive used and the condition of the flooring.

Dealing With Stubborn Adhesive

If you encounter areas where the adhesive is particularly stubborn, you may need to use heat to soften it. A heat gun can be effective, but be cautious not to overheat the vinyl, which could release harmful fumes. Always work in a well-ventilated area and wear a respirator for safety.

Removing the Plywood Subfloor

With the vinyl flooring removed, you can focus on removing the plywood subfloor. This process requires patience and careful work to avoid damaging the floor underneath.

Locating and Removing Fasteners

Use a cordless impact driver to remove all the screws holding down the plywood underlayment. Be thorough in this step, as missed fasteners can make removal difficult and potentially damage the original flooring.

Lifting the Plywood

Once all fasteners are removed, begin lifting the plywood sheets. Start at an edge and work your way across the room. If the sheets are glued down, you may need to use a pry bar to help lift them.

Dealing With Cabinets

In some cases, kitchen cabinets may have been installed on top of the plywood underlayment. In this situation, you’ll need to use a toe-kick saw to cut the plywood flush with the cabinets, as Silva did in the video above. If necessary, set the saw on a piece of MDF or plywood to prevent the blade from cutting too deep. An oscillating multi-tool with a flush-cutting blade can be effective for tight corners and spaces.

Revealing and Preparing the Original Floor

With the vinyl and plywood removed, you may find an original hardwood floor underneath. Here’s how to prepare it for refinishing.

Cleaning the Floor

Use a wet/dry vacuum to clean the exposed floor, removing all dust and debris. This step allows you to assess the condition of the original flooring and prepare it for refinishing.

Removing Residual Adhesive

You may find old adhesive residue on the original flooring. Use a detail sander to carefully remove this adhesive, revealing the wood beneath. Be cautious not to sand too aggressively, which could damage the wood.

Different adhesives may require specific removal techniques. Water-based adhesives often soften with water, while solvent-based adhesives respond to mineral spirits. Always follow safety instructions when using solvents.

Assessing Floor Condition

Carefully inspect the revealed flooring for any damage, such as warped or rotted boards. Minor issues can often be addressed during the refinishing process, but significant damage may require board replacement. Small gaps or cracks can be filled with wood filler or putty. After application, sand the area to have a level surface.

Refinishing the Original Hardwood Floor

With the original hardwood floor exposed and cleaned, you’re ready to begin the refinishing process.

Sanding the Floor

Start with a drum floor sander to remove any remaining finish and level the floor. Begin with coarse-grit sandpaper and progressively move to finer grits for a smooth finish. Sand in the direction of the wood grain. Hand sanders or edge sanders are useful for reaching corners and edges where the drum sander can’t. 

Applying Finish

Once sanding is complete, apply your chosen finish. Options include polyurethane, varnish, or oil-based finishes. Apply multiple thin coats for the best results, allowing each coat to dry completely before applying the next.

Use a high-quality paintbrush or foam applicator for the application. Follow the grain to avoid streaks and bubbles and ensure each coat is thin and even.

Our Conclusion

By removing your vinyl flooring and plywood subfloor, you could unveil gorgeous hardwood floors you never knew existed in your home. With the right tools and techniques, this project could be completed in a few days and add value and character to your home. Consult professional help for complex situations or if hazardous materials are present.