Modern construction technologies make it possible to install a high-quality floor without seams from quick-hardening mixtures. The process of filling a floor with high-tech building materials is not complicated and does not require special skills. It is quite simple to install a self-leveling floor yourself; this will significantly reduce the cost of construction work.
Types of self-leveling floors: variety of choice
It is possible to provide decorative design genderInnovative technologies for the production of self-leveling floors require a balanced approach when choosing them. It is necessary to take into account the surrounding interior, decorative design of the floor, material consumption when performing work, and the cost of purchasing the mixture.
To understand the process of laying self-leveling floors, you need to understand what types of coatings there are and how they differ.
Depending on the technical features floor installation work:
- The work is carried out with mixtures capable of self-leveling. Due to its properties, the material spreads over a plane in a layer 2-3 mm thick and becomes smooth when hardened. This floor is susceptible to mechanical damage.
- The filling method is carried out by uniform distribution mixtures on a plane with a special tool.
- An impregnation method in which the installation of a painting or thin-layer self-leveling floor is carried out using a roller or sprayer. In this case, the thickness of the layer is in the range of 0.1-0.5 mm, which does not make it possible to hide defects in the subfloor. To obtain a high-quality surface, the base is pre-polished.
In accordance with the resulting structure, floors can be:
- smooth;
- having moderate roughness;
- absolutely not slippery.
Floors vary in layer thickness Depending on the thickness of the layer, floors are:
- thin-layer. The size of the layer does not exceed 5 mm, which serves as protection against exposure external factors. The characteristics of the material and the condition of the base affect the amount of mixture consumption;
- self-leveling. The layer is within 2mm or less. Impact resistance various factors is at a good level, antistatic;
- highly filled. It has a thickness of more than 2 mm and is highly resistant. Sand, magnesite, and synthetic resins are used as fillers.
The high manufacturability of highly filled materials makes it possible to use them as decorative, specialized, and industrial materials. Depending on the aggregate used, the appropriate appearance of the floors can be achieved. The material has a relatively low cost and satisfactory strength characteristics, and is resistant to abrasive effects.
The characteristics and type of substance used as a binder determine the appropriate division of self-leveling floors. Let's look at each type separately.
Methyl methacrylate
Methyl methacrylate floors are poured in offices Methyl methacrylate resins are the basis for the production of this group of mixtures. This type of coating is universal. It is used when pouring floors of industrial buildings, not only inside buildings, but also outside them.
Resistance to temperature changes and exposure to direct sunlight explains the possibility of use in various fields economic activity. The required characteristics of the material are achieved by modification with the introduction of additives.
The material can quickly polymerize and can be used at subzero temperatures.
Hardening at a significant speed requires highly skilled installation, which must be carried out in a short time. In addition, the room where the work is carried out must be well ventilated, since the mixture has a strong, specific odor.
Epoxy
In the case of using epoxy resins as a base, it is possible to lay self-leveling floors on bases made of wood, concrete, or metal. The resulting thin layer allows it to withstand abrasive and chemical influences, has sufficient wear resistance, and also does not interact with oils, salts, and alkalis.
The scope of application of such materials is in objects related to various areas of industry. Their level of environmental friendliness allows their use in residential construction.
The positive qualities of floors made from such mixtures are the presence of increased resistance to environments with aggressive properties. In addition, you can create decorative coatings.
Reduced elasticity limits the range of application of the material in cases of impact or possible displacement of the substrate.
Cement-acrylic
Cement-acrylic floors The components of such a coating are polyacrylate copolymer, cement, and high-strength filler.
The technical characteristics of a floor made of this material correspond to the purpose intended by its developers, namely the food industry.
This coating is resistant to large quantity liquids, chemical substances, steam and various mechanical factors. The layers of such a floor do not undergo changes when cracking and do not allow slipping.
The installation of such a coating is quite a labor-intensive undertaking.
Polyurethane
The technological and aesthetic qualities of this coating determine its use in the construction of residential buildings. Of all polymer materials, polyurethane has the best strength and wear resistance. The material is able to withstand shocks, abrasive effects, and does not allow water to pass through. These qualities allow it to be used in retail, warehouse and industrial buildings and buildings.
Polyurethane - the most popular self-leveling floors When arranging floors using materials of this type, an increase in their consumption is observed.
In addition, a careful approach is required during the preparatory work of the foundation and low humidity atmosphere of the room.
Step-by-step instructions for pouring a floor
When starting work from the zero cycle, a screed is required to create the base of the floor. This will level out uneven areas and add strength to it.
An important factor when carrying out this work is temperature regime premises. It is unacceptable to apply the mixture at a temperature that does not comply with the manufacturer’s instructions. Violation of recommendations for the use of the mixture inevitably leads to defects.
Prime the base
Applying a primer layer to the screed is necessary to create a reliable connection between the floor material and the base. In addition, the primer helps to secure the screed.
To prepare the primer, use a drill equipped with a mixer attachment. After thorough mixing, a hardener is introduced into it, in the case of using a two-component system, and mixed again for two minutes.
Prime the base In order to obtain a mixture of appropriate consistency, a solvent is added. After this, the mixture is poured in a line that is located at right angles to the direction of stretching. The process of stretching the primer should occur in strips that originate from the walls. In this case, it is necessary to achieve uniform surface coverage. To reduce the consumption of the mixture, application is carried out using a spatula or rollers.
Upon completion of the hardening period of the primer material, all defects are eliminated by puttying. After the putty has dried, these areas are sanded.
If oiliness occurs, it must be eliminated.
Technique for the main stage of pouring the floor
The prepared mixture used to apply the base layer is poured onto the floor surface. The direction of the mixture layer is the same as when applying the primer. The composition is stretched using a squeegee, which creates the required layer thickness.
Tools for work After this, leveling occurs with a needle roller. His design features allow you to squeeze out air bubbles from the applied mixture, while giving it homogeneity. The movements of the roller when carrying out this work should be smooth and have different directions. It is not recommended to remove the roller from the mixture volume. Rolling is completed after complete removal of air and before a significant increase in viscosity.
The quantity of the two-component mixture must be such that it can be processed before it loses its viability. Acrylic particles are added to the freshly poured solution.
During the drying period of the mixture, the surface should be protected from interaction with water.
When carrying out work on organizing a self-leveling floor yourself, you should first carefully study the manufacturer’s recommendations on the packaging. If done correctly, the self-leveling floor will last for at least four decades.
The photo and video materials below will help you make a self-leveling floor with your own hands.
Self-leveling floor: photos of various solutions
In the photographs you can see the stages of the floor pouring work.
Layers of self-leveling floor 
Colored self-leveling floor 
Self-leveling floor at an industrial facility Do-it-yourself self-leveling floor: process video
The presented video materials will tell you about the stages of organizing a self-leveling floor.
Self-leveling floors occupy a special place. Its wide distribution is explained beneficial properties, among them: practicality, abrasion resistance, smoothness, ability to withstand humidity and temperature changes. If you want to update the design of the room, then self-leveling floors will be a valuable find, and the application technology will allow you to realize any bold design ideas.
What a master needs to know
If you install self-leveling floors yourself, you must remember one of the characteristics of such structures, which is thickness. Resistance to abrasive substances depends not only on the thickness of the floor, but also on the nature of the film-forming substance. classified by service life. Thus, thin-layer coatings have a minimum life, self-leveling floors have an average life, but highly filled floors are ready to last the longest. As practice shows, the most painstaking and important stage installation of self-leveling floors is the preparation of the surface that must be leveled. If the surface has a slight slope, the mass will flow to the lower corner.
Surface preparation
The installation of self-leveling floors requires the presence additional thermal insulation, which is laid on the floor slabs. A layer of expanded clay can act as insulation. The screed can be made of cement, water and sand. Among other things, the composition for arranging the rough surface can be purchased in a ready-made form in the store. The mixture is poured over expanded clay, and then leveled and left until completely dry.
For reference
The installation of self-leveling floors can be done by any home craftsman independently. The consistency of the mass for work should resemble liquid sour cream. The mixture consists of polymers, resins, and additives. The durability of the finishing coating and the quality of the work depend on how correctly the surface is prepared. The most practical base is considered to be a concrete screed, but some builders use wooden base. But experts advise against using wood as the base of the subfloor, as it is sensitive to changes in humidity and temperature.
Requirements for rough surface
If you will be installing self-leveling floors, it is important to prepare the concrete surface as correctly as possible: it must have normal humidity when applying the primer layer. Residual humidity should not be higher than 4%. After pouring the screed, it is necessary to leave the surface for some time, which is required to remove residual moisture from the concrete. If deadlines are tight and there is no time, you can use a two-component water-based one.
The technology for installing self-leveling floors involves grinding the surface of the screed if there are uneven surfaces on its base. Among other things, such manipulations will open the pores in the concrete, which will contribute to higher adhesion of the materials. If the floor is covered in the form ceramic tiles, then you can use such a surface as a base. To do this, the tiles are washed and degreased, and then treated with primer, which increases the quality of adhesion. If there are peeling tiles, they must be removed and cement mortar placed in the resulting empty spaces.
Padding
The device involves priming, which prevents air from entering the self-leveling floor system. This will prevent the formation of bubbles. Before applying the primer, the surface must be cleaned. You can use a roller during the priming process. In order to improve the adhesion properties of the self-leveling floor, it is necessary to pour fine-grained clean sand onto the still wet soil. Experts advise purchasing primer for concrete and not saving on it if the composition is absorbed fairly quickly. In this case, it is applied in several layers.
Filling the Base Layer
Work on the installation of self-leveling floors involves pouring the base layer. Its thickness should be approximately 3 millimeters; the mixture should be applied 6-12 hours after priming, which is true when using a polyurethane layer. If it is intended to be used, then the base layer is poured after 12-17 hours. The base layer is a continuous coating, which is built using the pouring method. The composition is evenly distributed over the surface, and if covered big square, then the mass should be filled in adjacent strips. The composition will spread and level out on its own. To apply the mixture, it is recommended to use a squeegee, which is a tool with an adjustable gap. With its help, you can apply a layer of the desired thickness.
Epoxy self-leveling floors must be installed in such a way that bubbles do not form in the composition. Before the mixture dries, the surface must be treated with a special roller, which has long spikes. The master should roll the base, moving in different directions. In this case, the tool should not be removed from the material. It is necessary to complete this process within 10 minutes, since after this period the composition will begin to increase viscosity.
If a two-component composition was used for the floor, then you need to prepare the amount of mixture that you will have time to produce before hardening. When rolling the surface with an aeration roller, the master must wear paint shoes, which have special metal spikes. Such a device will prevent damage to the integrity of the self-leveling coating. If you plan to take a fairly long break from work, then the entire instrument must be washed in a solvent.
Filling the finishing layer
A day after applying the base layer, you can prepare a mixture for installing a self-leveling floor, which will form the basis of the finishing coating. However, the interval between application of layers should not be more than 48 hours. The thickness of this coating should be approximately 2 millimeters. In order to improve chemical characteristics coating and ensure its shine, the filling of the floors is completed, which is applied in a thin layer. The seamless coating will be monolithic, and there will be almost no temperature shrinkage. However, you must remember to have expansion joints along walls and doors. The resulting space is filled with a special sealant.
The self-leveling floor must be installed according to the manufacturer's instructions. It is important to maintain the temperature regime. If the mixture is applied at a lower temperature than that specified in the instructions, then the mixture will harden for a long time, spread poorly, and its consumption will increase. The appearance of the coating after hardening may not meet expectations. If, on the contrary, the temperature is elevated, then hardening of the mixture will occur in more short time, but the quality of the composition will decrease, which will negatively affect the durability and appearance of the coating.
When carrying out such work, the room must be maintained constant temperature until the surface hardens. If it is too hot, it will cause bubbles to form. Industrial self-leveling floors, which are installed using the same technology, also involve applying the mixture to a surface previously prepared with a primer. If the temperature is sharply reduced during priming, this will cause condensation to form on the surface. Work should not be carried out under such conditions. It is recommended to protect the uncured coating during the day from any moisture coming onto the surface. If this happens, the curing process will be disrupted, the base may turn white, and pores and bubbles will appear on the surface. The floor must be kept clean and the room must have adequate ventilation.
Cost of work
Before you start pouring the mixture, you must lay the floor screed. Self-leveling flooring, which is not always installed by apartment and house owners, will cost more if you entrust the job to professionals. For example, laying a concrete screed will cost approximately 450 rubles. behind square meter. If you want to insulate the surface by adding an expanded clay layer to the system, then the work will cost 600 rubles. per square meter. Sand concrete screed can be installed by specialists for 550 rubles. per square meter. Quite often, self-leveling floors are supplemented with heating, while the arrangement of the preparation will be somewhat different, but will cost less - 350 rubles. per square meter. If you decide to install a self-leveling floor, an estimate drawn up by professionals will allow you to estimate the costs in advance. So, if the thickness of the floor does not exceed 30 millimeters, then you will have to pay 350 rubles for the work. per square meter. The finishing layer, the thickness of which does not exceed 10 millimeters, will cost 250 rubles. per square meter.
Conclusion
If you still can’t decide whether to choose a self-leveling floor as a finishing coating, then you should familiarize yourself with it in more detail. technical characteristics. Such systems are highly wear-resistant and can withstand the effects of aggressive household chemicals, and are also ideal for subsequent finishing with any materials. If you do not install other coatings, the surface will be easy to clean and hygienic. In addition, during operation, the materials at the base of the self-leveling floor do not emit toxic substances or vapors harmful to human health. Such systems are completely harmless to external environment, which forces many buyers to choose in their favor.
Industrial concrete floors are generally used in commercial purposes– in warehouses, parking lots, etc. industrial premises. Their main difference from conventional concrete floors is their high strength, quick pouring and resistance to various influences and loads. Next, we will take a closer look at their features, types and consider manufacturing technology.
General information
Industrial premises are subject to increased loads, frequent temperature changes, and operation in higher level humidity, etc. Therefore, concrete industrial floors are made from special mixtures, and sealants, heat and waterproofing materials are also used.
Such floors are especially in demand in shops and shopping centers. However, they are also used in private construction, for all kinds of outbuildings and garages, which are constantly exposed to significant loads.
Main types of industrial floors
All concrete coatings can be divided into two groups:
- Bulk;
- Regular.
Not very reliable, as their surface is prone to cracking and abrasion. Therefore, they are not suitable for industrial use.
Concrete industrial self-leveling floors come in the following types:
| Topping | It is a special durable layer that is applied to freshly poured concrete. The dry mixture is thoroughly rubbed into the coating using trowels. As a result, its resistance to stress and durability increases. It must be said that there are several types of topping, which differ depending on the expected loads. The mixture may include substances such as: · Slag; · Quartz; · Cement; · Modifiers. |
| Industrial vacuum floors | They are a combination of topping and technology for eliminating air bubbles from the poured coating. In this case, not the entire mass of the coating is compacted, but only the top layer using special equipment. The disadvantages of such floors include their high price, as well as poor resistance to impacts. |
| Magnesium industrial floors | Contains magnesium binder. The advantages of such a coating include the following: · No dust formation; · High wear resistance; · Resistance to cracking; · No shrinkage; · Good durability; · Resistance to mechanical stress and blows; · High elasticity; · High speed drying - the coating is ready for use a few hours after pouring. If a normal pour requires a layer thickness of at least 8 cm, then the thickness of this mixture can be only 1 cm. |
| Multilayer floors | If the floors will be used in difficult conditions, experts recommend using a complex multi-layer structure. Such floors are reinforced with reinforcement or fiber, and also have a waterproofing and thermal insulation layer. As a rule, their thickness is from 25 centimeters. |
Pouring technology
The technology of industrial concrete floors may vary depending on the type of coating, however, most often it consists of the following stages:
- Preparations;
- A rather complex process of laying and compacting the surface;
- Hardening.
Now let's take a closer look at all these stages.
Preparation
The preparation of the base is carried out as follows:
- First of all, it is necessary to clean the surface from dust and dirt, as well as flaking and crumbling areas.
- Then the highest point of the surface is determined, from which the thickness of the layer must be measured to be at least 10 cm. If the concrete is laid on sand, then the thickness of the screed must be at least 15 centimeters. The zero level should be marked on the wall along the perimeter.
- Next, reinforcement is performed; for this, a special reinforcing mesh or metal rods are laid. The reinforcement must be located in the thickness of the concrete, so wooden blocks are placed under it.
- Then the installation of beacons is carried out, for which a special metallic profile. Installation of beacons is carried out on lumps of gypsum mortar. To ensure precise installation of the slats, you can screw in self-tapping screws along the edges, which will allow you to adjust the height of the beacons from the floor.
As a result, all beacons should be located in the same horizontal plane and correspond to the zero level. - To complete the preparatory work, damper tape is glued to the perimeter of the wall at the junction of the floor and the wall.
Fill
The filling instructions are as follows:
- The solution is distributed over the floor and leveled using the rule.
- Concrete must be compacted using vibrating slats or deep vibrators.
- The final leveling of concrete is most often carried out using the rule. It must be said that even when using modern concrete pavers, experts do not completely abandon leveling the surface with their own hands using the rule of thumb.
- After pouring, it is necessary to give the surface time to “cur”. Typically this takes about 6 hours.
Advice!
Before pouring the floor, it is necessary to provide openings for communications.
If this is not done, you will subsequently have to perform diamond drilling of holes in the concrete.
Hardening
Next, hardening dry mixtures – topping – are rubbed into the surface. This operation can be performed manually or using special trolleys. After applying the topping, it is sanded aluminum rule or special machines.
In the photo - performing the topping
Note!
To ensure uniform drying of the concrete, it must be periodically moistened with water using a paint roller during the first 10 days.
After the concrete has hardened, if the surface area is large, expansion joints are made. To do this, reinforced concrete is cut with diamond wheels.
If self-leveling floors are used as reinforcement, you must wait until the concrete has completely dried, then pour out the liquid solution and level it with a special spiked roller.
These are, perhaps, all the main features of industrial concrete flooring.
Conclusion
An industrial concrete floor is a reliable coating that can withstand very heavy loads and operation in unfavorable conditions. There are several options for obtaining such a coating, each of which has its own advantages and disadvantages, so the choice should be made depending on the tasks assigned to the floor covering.
You can get more information on this topic from the video in this article.
Depending on where the concrete floor will be used, the technology for its manufacture depends. Special attention requires technological process manufacturing a concrete floor in an industrial area, the main task of which is to withstand enormous loads. As an alternative to traditional coverings, modern polymer floors are increasingly installed in apartments, houses and warehouse areas. All types of concrete floors and methods for pouring them will be discussed in this article.
- durability;
- strength;
- moisture resistance;
- low maintenance requirements;
- non-slip coating;
- absence of mold and mildew, to which wooden floorings are susceptible.
Concrete floors photo
All this makes it a winning option for flooring, as in residential buildings, and in wet and unheated rooms. If you make a concrete floor with your own hands, following all the rules, it will last for decades without significant damage.
Types of concrete floors
Conventionally, concrete floors are divided into 2 types: classic concrete mortar and bulk polymer.
- If a concrete floor is made in a residential area, for example in an apartment, then it is made according to the standard scheme.
- The situation is much more complicated in warehouse or production areas. Even before creating a building design, you need to calculate the expected loads that will be exerted in the future during operation. In addition, the degree of exposure to chemicals and temperature changes are determined, all of which together have a strong impact on the concrete floor.
- When pouring the floor in a warehouse, calculate the height of future racks and their maximum load. This will help to give a realistic assessment of the load-bearing capabilities of the soil, which serves as the underlying layer. Taking all this into account, you will get a cost-effective concrete floor project, since the reinforcement method, concrete grade and pouring thickness will be correctly selected.
Self-leveling concrete floors
- Self-leveling polyurethane floors have an aesthetic appearance without additional treatments of the top layer. Depending on their purpose, such coatings have varying degrees of elasticity and strength. They long time withstand heavy loads, vibration, shock and temperature changes.
- Self-leveling epoxy floors They have high strength characteristics, are resistant to abrasion and chemical attack, and are also available in a wide range of colors. However, its elasticity and impact resistance are low, but this can be corrected by adding quartz filler to the composition.
- Acrylic self-leveling floors They are characterized by high resistance to strong temperature fluctuations and tensile strength. And thanks to their resistance to ultraviolet radiation, they are often used in open areas.
Advice: when choosing one type or another, you need to pay attention to the composition. If it contains additional strengthening additives, then it is called highly filled. When the composition is poured in its pure form, it is called thin-layer.
DIY polymer concrete floor
Tools for installing self-leveling concrete floor:
- container for mixing the solution;
- needle roller;
- wide metal spatula;
- tape, screwdriver with mixer attachment;
- level.
The mixture will need to be prepared, since it is always sold in the form of two components. Mix the solution immediately before use.
Stages of work
- The installation of a polymer concrete floor begins with surface preparation. The service life of the finished floor depends on the quality of this work.
- If the floor is wooden, then it should be sanded and dried. Next, fill all the seams between the boards with sealant and prime them. It is also important to check the strength of fastening of all boards so that they do not “walk” under your feet and there is no creaking.
- The concrete base, if it is old, is repaired using a sealant that fills all the cracks. If its surface is too damaged, it is recommended to remove the top layer and sand it. Due to the high porosity of the concrete base, it is primed in any case.
- To gain maximum strength, during work it is necessary to maintain a temperature regime of 5-25 ° C.
- The prepared solution should not contain air bubbles, be evenly mixed, and have a consistency similar to kefir. You should work with it quickly, so while one person pours the solution onto the base, the second one immediately distributes it over the surface with a wide spatula. When walking on a freshly poured floor, you must wear special shoes with high spikes. Craftsmen make them themselves by screwing a piece of board with nails onto an old pair of shoes.
- After pouring the area, it is treated with a needle roller for 30 minutes to remove any air bubbles that inevitably form during pouring. After 30-40 minutes, the self-leveling floor will set and it will no longer be possible to bring it to perfection.
- On average, the consumption of dry composition is 1.5 kg/m2 - this is a layer thickness of 10 mm.
Advice: when working with self-leveling floors, harmful fumes are present. Therefore, it is recommended to work in means personal protection. In addition, the room must be provided good ventilation, this will speed up the evaporation of resins and the speed of setting of the floor.
- After 3 days, pour finishing layer, the thickness of which is only 2-3 mm. When it gains strength, it can be treated with polyurethane varnish if desired. This is necessary not only for beautiful appearance, but also for better resistance to chemical compounds.
- The frozen floor is a solid base, but it is often additionally decorated with a pattern. It is printed at a scale of 1:1, laid on the floor and filled with a transparent layer of self-leveling floor.
DIY industrial concrete floor
- First you need to familiarize yourself with the floor design, which should contain data on the location of expansion joints. As well as an assessment of the characteristics of the soil, or rather the degree of its compaction (which should be at least 0.99). This will prevent cracking and destruction of the concrete site due to possible subsidence of the earth. If the density is insufficient, and there is no time to break off the construction for another year, then the surface is compacted with a roller or vibrating plates.
- Then they do sand cushion 15-20 cm thick. The height difference can be determined using a laser level; it should not exceed 5 cm.
- If it is poured over an old concrete base, then you must first remove all protruding metal or wooden elements. If there are large cracks or trenches, they are filled concrete mixture and level.
- The correct thickness of a concrete floor affects its durability. Often, savings are made at this stage of construction, which leads to subsequent cracking and destruction. Eat general recommendations, in which the thickness of the pour on an existing old concrete slab should not be less than 10 cm, and on a soil base - 15 cm.
- Since production areas are always large, they are filled in separate sections. As a result, seams are formed. Their main danger is uneven subsidence of the soil and the formation of differences in height in these places. Therefore, it is advisable to place them in the area of racks or areas where active movement and use of forklifts is not provided. Also, the size of the areas to be poured depends on the location of the load-bearing columns, which is most often 5-6 m. The area must be filled completely; it cannot be left unfinished until the next day.
- Next, lay a layer pvc film. It will prevent the leakage of cement laitance from concrete into the ground. And when pouring onto an existing one concrete base, will divide new layer from the old one, thereby preventing possible cracking due to uneven shrinkage of individual sections.
- It is also important to create a floating floor effect. To prevent the floor from deforming during linear expansion of concrete under the influence of temperatures, a layer of foam plastic or isolon 8-10 mm thick is laid along the entire perimeter of the junction with the foundation and communications.
- Next, guides are installed along the finished floor mark. It is best to use special metal guides, which can be removable or non-removable. Since they are produced in a wide range of sizes, choosing them to suit the desired design thickness is not difficult.
The most popular non-removable guides for installing a concrete floor:
- Combiform- made of steel with perforation to facilitate construction. Has a polymer head. This rail form is mounted on prepared reinforcement by welding. After the concrete has hardened, the deformation head is removed, and the resulting seam is filled with sealant.
- NS-Omega or Delta- this is a rigid metal guide that is left in the solution. Has an expansion joint. Also welded to fittings.
- Treform- concrete guide, has high rigidity, which guarantees no deflection when pouring the solution.
- You can use a channel or metal pipe. They are placed along the edges of the pouring area, and after the poured area has hardened, they are removed. Such gaps between sections create a shrinkage gap. The guides that are located along the walls are removed immediately while the solution is soft. If the project provides, then at the installation stage of the guides, trays for draining water, hatches for wells, etc. are also installed.
- Next comes the reinforcement stage. Depending on the requirements for load-bearing capacities specified in the project, the concrete floor is reinforced with metal mesh, fiber, or a three-dimensional frame is knitted. Often, fiber is used not as independent reinforcement, but for additional strength to a metal frame.
Advice on choosing reinforcement:
- the finished mesh is chosen for areas with low load, for example, pedestrian areas or parking lots passenger cars. Installation is carried out with an overlap of 1-2 cells and secured with wire;
- the volumetric frame is chosen for greatest strength. The diameter of metal or fiberglass rods corresponds to the design strength of a particular floor. They should be located in the thickness of the concrete, without touching the base. To do this, place them on special frog supports. All rods are connected to each other with a minimum overlap of 20 cm;
- steel fiber reinforcement significantly reduces the labor costs and cost of concrete industrial flooring. On average, its consumption is 30-35 kg/m3 of concrete solution. It must be added before installation at the construction site. Fiber is added to the automixer and mixed thoroughly. This method is only suitable when using high quality concrete and a carefully prepared sand base.
- The concrete solution is supplied via a pump from an automixer. Filling the card should be done in one step. To achieve high strength of the top layer, it is not recommended to add antifreeze additives to concrete.
- When the entire card is filled with solution, it is compacted and air bubbles are expelled using special equipment, for example, ejectors. This is done most carefully along the walls and supporting elements. The entire pouring area must be passed at least 2 times.
- After filling all the cards, the solution is left for 3-4 hours to set (in rainy or cold weather this time may increase). And they begin smoothing the concrete surface with special machines for concrete finishing work. To make sure that you can begin work, you need to step on the concrete, the boot mark should go deeper by 2 cm, but no more.
Tip: sometimes more is used for finishing quick method vacuum equipment, but this method may cause too much shrinkage. Therefore, it is recommended to wait for the natural curing of the concrete solution.
- Concrete finishing machines for mechanical processing are compact, manual or self-propelled. In both cases, cleaning discs are used. Having passed the entire area at low speeds, a strengthening agent is evenly distributed over the surface. mineral composition. The recommended consumption of which is 5-9 kg/m2. It is left to gain strength. It cannot be moistened; it must take all the necessary moisture from the concrete floor. As soon as it darkens, you can begin further machine grouting.
- As soon as the work is completed, immediately distribute the remaining half of the hardener and also wait for it to gain strength and darken. Upon completion, grouting is carried out several times, changing the direction of movement.
- For maximum strength gain top layer, it is rubbed with blades, which are first set with a small angle of inclination and gradually increase it as work progresses. The result is a smooth surface.
- When concrete hardens, it is important that moisture does not evaporate from it. To do this, use a sealer (a composition that promotes moisture retention). It is sold in liquid form and is applied with a roller. To reduce the cost, you can simply cover the entire area with film. IN hot weather It is recommended to additionally moisten the film once a day.
- When the concrete has set, grooves are made along the fresh coating with a diamond disc perpendicular to the cold seams. They will act as heat shrink seams. Their depth is 1/3 of the thickness of the fill.
- Foamed polyethylene is placed in the seam. Its thickness should be slightly larger than the width of the seam. It is compacted to a depth of 1 cm. Then the remaining space is coated with sealant and the entire space is filled with sealant using a gun.
- It is important to use a dry hardener for industrial concrete floors. Thanks to its composition with high-quality cement, the coating has high wear resistance and low water absorption characteristics;
- When using a hardener, you must be prepared that after it dries, microcracks may form on the surface due to shrinkage; this does not in any way affect the quality of the floor.
Covering the floor with concrete is a cost-effective option flooring for any premises, from apartments to production areas. For a low price it turns out really durable coating, which can be decorated with any flooring material.
DIY concrete floor video
The technology for creating a polymer self-leveling floor is complex and time-consuming, especially if we're talking about about 3D coating.
Specialists involved in the creation of polymer floors must have experience not only in pouring this type of mortar, but also in other related construction work.
This requirement is associated with the step-by-step actions of installing a polymer self-leveling floor, which also includes rough work with concrete.
Just a few years ago, polymer self-leveling flooring was used for pouring only in industrial buildings with high levels of mechanical or chemical influences.
Over time, the material has been modernized.
High quality coating and appearance attractive appearance have done their job, the polymer floor has found its application in civil engineering. More recently, amazing technology has emerged that allows you to create a 3D coating.
Today, without resorting to the services of craftsmen, polymer self-leveling floors are created by the owners themselves in their apartment.
Before moving on to the diagram for installing self-leveling floors with your own hands, it is worth getting acquainted with their types and purposes.
Types and features of self-leveling floors
Currently on construction market Two types of self-leveling floors are in high demand: polyurethane and epoxy.
Polyurethane self-leveling coating is an industrial floor that is used as floor surfaces in warehouses, hangars, and production facilities.
They can also be used in parking lots and buildings Food Industry and industrial refrigeration units.
Industrial polymer floors are endowed with a high degree of wear resistance and are resistant to mechanical and chemical influences.
Due to their unique structure, industrial self-leveling floors can perfectly cope with deformation loads on the base.
Epoxy polymer floors (another name is “liquid linoleum”) also have high strength characteristics and resistance to chemicals.
In addition, epoxy self-leveling coatings differ smooth surface and a wide selection of colors.
Contains epoxy polymer material There are no solvents, so the coating does not emit any pungent odors.
This type of flooring is used for making floors in residential premises with your own hands.
The 3D technology for creating coatings stands out. This innovation is currently only affordable for people with above-average income. In an ordinary apartment or a simple private house, 3D coating is practically not found.
Preparing the base for pouring self-leveling floors
The polymer coating pouring technology involves performing the following step-by-step actions:
- preparation of the concrete base;
- device of the first - main layer;
- applying the second – decorative layer;
- the third stage is the varnish layer.
If 3D creation technology is used, then such a drawing is created according to a completely different scheme.
A properly prepared subfloor base is the key to obtaining a high-quality self-leveling surface.
As a rule, epoxy polymer coatings are applied to a concrete base, which has the following requirements:
- evenness of the plane, complete absence of defects on the base (cracks and gouges);
- arrangement of waterproofing;
- cleanliness of the coating, absence of greasy oil stains;
- moisture content of the concrete base is not more than 4%;
- The screed is installed using cement of at least M 200.
Therefore, if the base of the floor leaves much to be desired, it is recommended to apply a new concrete screed, under which waterproofing material is laid with your own hands.
It will take several days for the base to ripen, after which you can begin priming it.
A carefully primed base should have a surface that visually resembles sandpaper, which will indicate its high adhesive properties and allow for ease of application of the polymer solution.
Decorative elements and a set of necessary tools
In addition to the fact that epoxy polymer coatings differ from all other floor finishes high level performance indicators, they can surprise you with their decorative properties.
Such floors allow you to create an original surface that has never been used anywhere else with your own hands.
To do this, just stock up on decorative elements that you can use sea pebbles and small shells, coins or colorful buttons.
Subsequently, you can lay out a beautiful mosaic from them.
Flooring is not limited to the above-mentioned decoration method.
In some places, such a floor is designed in the form of an artistic system, which involves the use of stencils and the application of certain patterns with paints.
That is why the self-leveling floor can be safely called a bright representative of decorative surfaces.
Separately, it is worth mentioning the 3D design technology. Of course, such 3D coating is not cheap, but it is worth it.
Before installing a self-leveling floor, you must have the following set of tools and auxiliary materials on hand:
- a container with a volume of about 30 liters for preparing the composition;
- shoes with spikes (paint shoes) for walking on the treated surface;
- simple spatula, for use in hard-to-reach areas;
- a squeegee spatula, which, using an adjustable gap, will allow you to evenly distribute the mixture;
- whisk, low speed drill;
- aeration roller (with spikes) to remove air bubbles from the freshly laid layer.
Pouring a polymer self-leveling floor
The technology by which liquid linoleum is applied consists of two stages. At the first stage, the underlying layer is poured with your own hands, at the second stage the front (finish) coating is applied.
This is how liquid linoleum is obtained.
The components of the first coating are two components: fine quartz sand and liquid epoxy polymer material.
The liquid polymer composition is distributed over the base in order to completely hide minor defects. In this case, the thickness of its layer should not exceed 1.5 mm.
Work begins no earlier than the primer has dried. It takes a day for the liquid layer to dry.
Using a level, determine the deviation of the floor plane.
If the thickness of the base at the highest point should be about 2 mm, then an acceptable thickness of the epoxy layer at the lowest point is approximately 10 mm.
The finished liquid solution is distributed over the base using a metal spatula, focusing on a high point on the floor surface. The thickness should not be greater than stated.
The liquid solution in portions must be prepared quickly and according to instructions, with a maximum time period of use of no more than 10 minutes.
It will take at least a day to polymerize the applied layer. If defects are found on the base, then the self-leveling linoleum is cleaned with your own hands using abrasive materials.
After this, the process of applying the front finish is repeated again.
At the next stage, they proceed to applying the finishing polymer layer.
Polymer linoleum is poured onto the floor surface in strips, their thickness is leveled using special tool called a squeegee.
In hard-to-reach areas of the apartment, a spatula is used to distribute the layer.
After the self-leveling linoleum has been completely distributed over the base and covered the entire area to be treated, you need to walk over the surface with a needle roller with your own hands.
The technology involves the use of an aeration roller so that the thickness of the polymer layer gets rid of air bubbles, negatively affecting the quality of the polymer floor.
In order to further protect the polymer coating, self-leveling linoleum in an apartment can be treated with wear-resistant varnish. The thickness of the coating does not matter in this case.
In rooms with a large area, the technology for applying polymer self-leveling floors yourself is slightly different from installing floors in small spaces.
Before pouring linoleum, the base is divided into several sections using expansion joints.
After the epoxy floors are poured, expansion joints sealed with a sealant specially created for self-leveling floors.
In conclusion, it is worth noting that self-leveling polymer floors, in addition to decorative functions, in the apartment have a lot of advantages, one of which is sufficient thickness.
Therefore, such coatings are ideal for underfloor heating systems and are highly durable and practical.
In addition, they are endowed with the ability to respond to temperature changes without changing the structure.
Floors made from such materials are vapor permeable, which means that polymer coating breathes.
After reading the article, you learned a lot about polymer self-leveling floors, which can be found in the apartment (even in 3D version). But often industrial enterprises also choose self-leveling floors.