This section provides an overview for self leveling material as well as their applications and principles. Also, please take a look at the list of 11 self leveling material manufacturers and their company rankings. Here are the top-ranked self leveling material companies as of July, : 1.LYONS MANUFACTURING, INC., 2.ARDEX Americas, 3.CTS Cement Manufacturing Corporation.
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Self-leveling materials are gypsum or cement-based natural flow materials.
Self-leveling material is characterized by its ability to form a level and uniform level simply by pouring, and is also known as a leveler.
It is a revolutionary flooring material when compared to mortar, which has a similar role to that of self-leveling materials. While mortar finishes vary greatly depending on the skill of the craftsman, self-leveling material can be poured in and then broken in with a tonneau to complete a smooth floor base quickly.
Self-leveling materials are used to prepare floor subfloors with a smooth concrete surface.
Applications include buildings, condominiums, schools, hospitals, factories with heavy vehicles such as forklifts, parking lots, food factories, kitchens, and waterproof basements on rooftops. It is also used for underground adjustment in the preliminary stage of applying finishing materials such as tiles and other floor coverings.
Compared to mortar, which performs a similar function, self-leveling materials are more expensive in terms of material cost, but the short construction period helps to keep costs down.
However, it is difficult to obtain the thickness of self-leveling material in a single installation, and overlaying is required for thicknesses of 20 mm or more. In such cases, mortar is more suitable.
The principle of the self-leveling method using self-leveling materials is that a slurry (suspension) of gypsum and mortar poured onto the floor surface naturally flows to form a smooth floor surface.
The self-leveling process follows the following steps:
Pre-construction preparation includes level checking and marking. Marking out is the process of drawing out reference lines that serve as horizontal and central positions, such as the centerlines of columns and finished surfaces of walls. To prevent the self-leveling material from leaking outside, gaps are filled with mortar to prevent direct sunlight and wind.
The substrate is cleaned with a special brush as a pre-treatment. Oil and protrusions are treated so that the self-leveling material and the floor can bond well.
Primer is applied and allowed to dry to provide adhesion to the subfloor surface. Primer is a base coat applied to improve the adhesion of materials that do not bite well to paint.
After completing the above preliminaries, the self-leveling material is poured. When pouring the leveling material, ripples and air bubbles generated from the frame may remain as shapes, so if necessary, use a trowel to even out the material.
Details are matched to the ink or level point using a trowel. Finish by pouring gently, quickly, and evenly.
After pouring is completed to the finish level, the curing period begins. Avoid rapid drying until curing is complete. Close the windows to stop ventilation and reduce surface wrinkles caused by wind.
After curing is complete, the self-leveling material is still in a state of excessive moisture, so once curing is confirmed, windows are opened to improve ventilation and promote drying.
Finally, as a pre-completion inspection, we inspect the level of the building after it is ready for walking. We check all areas for joints, joints, and height differences. Any joints, bubbles, etc. that may have occurred will need to be corrected.
Self-levelling materials can be classified into two categories: gypsum-based and cement-based.
It has the property of not expanding or contracting during curing due to hydration reaction. This gypsum-based product has high dimensional stability and is resistant to floating and cracking.
Many cementitious materials feature high strength, and some can be used externally. After curing, they are also characterized by their resistance to water.
Laying concrete over large areas may seem easy enough for most DIY-ers, but wet concrete is heavy and difficult to move. Hiring professionals to install concrete floors helps reduce the risk of uneven floors.
However, if you notice that your concrete floors are uneven, you do not need to panic. Uneven concrete floors are fixed or repaired through a process known as floor leveling.
Self-leveling concrete is the best solution for repairing concrete floors. This concrete is excellent for concrete floors that have cracks, are sunken, or are uneven. It is a great way to level unleveled surfaces while giving old concrete floors a fresh look.
What is self-leveling concrete?Self-leveling concrete is a polymer-modified cement used to create high-compressive smooth flat surfaces. It does not require large volumes of water and can work on any non-flexible surface, including wood, ceramic tiles, plywood, and concrete.
There are two types of self-leveling compounds; acrylic and water-based concrete. Acrylic concrete is made by mixing cement powder with liquid acrylic polymer.
The water-based self-leveling concrete uses water instead of the acrylic liquid for mixing. They both come as a bag of powder containing the latex compounds for mixing. The water-based self-leveling concrete type is much easier to use and ideal for beginners.
Self-leveling concrete is poured in liquid form and spread in place using a gauging tool. A single pass of self-leveling concrete is usually 0.25 to 1.5 inches thick. The finished product is smooth and flat, with superior compressive strength to traditional concrete floors.
After application, the concrete can be decorated using overlays or concrete stains and dyes. Self-leveling concrete is relatively popular among architects and property owners because of its many advantages over traditional concrete.
It is easy, quick to install, and useable before or after construction. It also creates smooth and flat floors on tile, plywood, or concrete floors. Therefore, self-leveling concrete helps reduce instances of damage and repair costs.
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When to use self-leveling concreteSelf-leveling concrete is quick and easy to install and is therefore quite DIY-friendly. Use self-leveling concrete to repair slightly uneven floors in your home. Use a spirit level to accurately measure the degree of unevenness, then pour the compound and spread it out.
There are many applications for self-leveling concrete. It is perfect for upcycling settled or cracked floors. You can also use it to smoothen and flatten rough and uneven basement floors.
You can also use it as a standalone finishing material, durable enough to withhold daily wear and tear. This makes it suitable for use in retail stores, warehouse floors, institutional facilities, and industrial locations.
For decoration, add stains, pigmented color dyes, and saw cuts, and for a more polished look, consider mechanical polishing.
When not to use self-leveling concreteDespite its advantages, self-leveling concrete is not always the best option. There are some instances when you should not use self-leveling concrete.
Do not use self-leveling concrete without the help of a trained professional. The compound dries very fast and only allows a ten to twenty-minute window from pouring to spreading before it starts to harden.
Self-leveling concrete is best suited as a standalone or subsurface flooring for interior flooring. However, it is unsuitable for outdoor flooring as it doesn&#;t hold up very well in harsh conditions.
Polymer-mixed, self-leveling concrete also does not cure very well on non-horizontal surfaces. It will therefore be unsuitable for use on vertical walls. It is also not suitable for use where heavy machinery or harsh chemicals are applied.
It is also advisable to avoid using self-leveling concrete on floors with structural damage. It only fixes the surface, so the problem will reoccur if the underlying floor orientation is in bad shape. Perform structural repairs before applying the leveler to prevent the floor from sinking again.
Self-leveling concrete is also unsuitable for repairs in large areas due to its fast drying time and increased cost. A self-leveling concrete bag is more expensive than a bag of ordinary cement.
Finally, do not use self-leveling concrete unless you can clean it right after application. Concrete is very sticky and can stain surfaces and clothes.
How to use self-leveling concreteIt is vital to ensure there&#;s no structural damage before installing self-leveling concrete. If the unevenness is due to structural damage, you must get that fixed first.
Next, you need to determine the moisture level of the concrete floor. Moisture is normal in concrete, but a high moisture level puts the leveling compound at risk of gradual degradation. The slab must, therefore, be tested to ensure that the moisture level is within acceptable levels.
This can be done using &#;the relative humidity test using in situ probes.&#; Once you know the floor is good enough to work on, you can start the installation process. Start by preparing the floor and filling the cracks, then apply primer, mix the concrete and leave to dry.
Clear the floor by removing the room's furniture, appliances, and baseboards. Remove everything moveable, so you get a good finish. Once the room is empty, clean the floor and remove dust. For best results, sweep first and then vacuum. The clean surface is ready for priming.
Use a filler and a sealer to fill the larger cracks in the concrete floor. To do this, place the nozzle of the filler bottle in the cracks and squeeze out enough filler to fill the crack. You can also press the filler into the cracks to ensure they are adequately filled.
Ensure you have filled all the cracks before proceeding to the next step to avoid wasting the leveler. Allow the filler and sealer to dry, and then prime the surface.
Once all cracks have been filled, use a soft-bristle push broom to apply and spread the primer. Use downward pressure to spread the primer thoroughly, ensuring you push it into the pores of the concrete. Allow the primer to dry for 3-24 hours.
Pour the leveling compound into a bucket and add some water. Use a mixing paddle to mix it until you have achieved the right consistency. Work fast and mix one bag at a time because the compound dries fast.
Since you only have a 10-20 minute window before the compound begins to harden, you should work with a partner. An extra pair of hands is great because one person can mix the compound while the other installs it.
Once the compound is installed, let it dry according to the instructions on the bad. Self-leveling concrete typically takes 4-24 hours to dry, so you should be able to walk on it after 4 hours. Give it at least 24 hours to dry completely before installing any other flooring.
SummarySelf-leveling concrete is a polymer-modified cement used to create high-compressive smooth flat surfaces. It is an ideal alternative to regular concrete because it is easy to use and fixes uneven floors in just 4-24 hours.
Ideal for DIY projects, self-leveling concrete should only be used when there is no structural damage to the existing concrete floor. It is suitable for use on wood, tiles, and concrete.
Self-leveling concrete is best for relatively small spaces because it is expensive compared to cement covering square footage at a much lower cost. Ultimately, self-leveling concrete offers a quick and easy fix for uneven floors.
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