That 3 AM seam blowout in Tulsa set me back 5 hours

I had a 4,000 square foot office install last Thursday in Tulsa, and I was running the seams with a hot iron like I always do. Around 3 AM, I hit this one seam near the hallway transition, and the backing just split open, not a clean cut, it shredded on me. Turns out the previous guy had patched that area with a scrap piece that had a different backing type, and my iron melted it instead of bonding it. I sat there staring at the 6 foot gap for a solid 20 minutes before I realized I had to cut out a full 10 foot section and relay it with fresh carpet from the roll. That little fix took me 5 hours because I had to re-stretch the whole row and re-seam two other spots that shifted when I pulled the bad piece. Has anyone else run into mismatched backing from a prior repair job, and did you find a way to spot it before you cut? I am checking the underside with a flashlight now, but that only helps if the patch is visible.

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