The process and apparatus herein is used for achieving multilevel mechanical embossing of a fused or cured wear layer in register with a print on an expanded foam thereunder. The expansion of the decorative foam and fusion of the wear layer are carried out and then the back of the foam is cooled by wetting and liquid evaporation. The wear layer is maintained at a high temperature for embossing and is embossed with registry between the embossed pattern and the printed pattern on the foam. Just prior to embossing, the decorative foam-wear layer web is wrapped around the backup roll of the embossing apparatus, and after embossing, is wrapped partially around the embossing roll of the embossing apparatus.