Surface Preparation for Industrial Flooring

Surface Preparation for Industrial Flooring

For long life flooring treatment, bonded flooring treatment stands at peak in its performance than the un-bonded systems. For any type of bonded flooring treatment, 80% of failure will be the results of improper application process. Application process, includes steps like: Surface preparation, Tools and Tackles Used for Flooring Treatment, Staging of Products at work place, Mixing of Products, Pouring / Placing of Flooring Products and Finishing of Flooring Products. But this is not the end of the flooring treatment, this continues with Maintenance of Industrial Floor also.

The entire flooring treatment bonds on the surface so the preparation of surface is very important, if not done properly it will a major prat of failure. The flooring treatment needs to be bonded with the surface and then only the treatment can perform its optimum level or else it will fail.

Have a look in to the following images:

1. Laitance: Is a weak friable layer of fine particles of cement and fine aggregates on the surface of concrete because of with the addition of too much water. Any flooring treatment, installed on Laitance, will de-bond very soon.

2. Damaged portions: Concrete gets damaged because of high impact, low surface strength, warping of concrete panels, Spalling of concrete, etc. These portions shall be removed in defined pattern and refilled with Structural Grade Polymer Modified Repair Mortar.

3. Honey comb / Pot holes: Honey comb are the hollow spaces and cavities in concrete mass on the surface or inside the mass. When these honey combs are at the floor top surface, it empty space opens, and it called as pot holes. This is because of: Improper vibration during concrete, less cover to reinforcement bars, use of very stiff concrete, use of more percentage of bigger size of aggregate in concrete. These shall be exposed by carrying out the process of CPS (Concrete Surface Profile) and then it shall be filled using Structural Grade Polymer Modified Repair Mortar or Rapid Drying and Hardening Repair mortar.

4. Segregation: Segregation in concrete is a case of particle segregation in concrete applications, in which particulate solids tend to segregate because of differences in the size, density, shape and other properties of particles of which they are composed leaving weak surface at top. These portions shall be removed in defined pattern and refilled with Structural Grade Polymer Modified Repair Mortar.

5. Oil Contamination: Practically, it is not literally possible to make the penetrated oil to remove completely. Applicator’s put their effort by flame cleaning. But no matter, whatever the process conducted, it is recommended to check the bond strength of the proposed treatment by site sampling and testing. It is always better to remove and re-fill the portions with Rapid Usable Cementitious Screed / Self levelling compounds (underlayment or topping).

6. Dense / Smooth surface: Be it is PolyUrethane Flooring Treatment, Epoxy Flooring Treatment, Or Cementitious Flooring treatment, for any bonded flooring system, it is always better to have good bond to the surface. Flooring treatment usually bonds to the surface in 2 ways, i.e. by chemically, or mechanically. To enhance the bond mechanically, surface needs to be prepared for the required CSP. CSP (Concrete Surface Profile) shall be selected as per flooring treatment thickness based on the client’s decision about – Which Flooring Treatment for What Purpose?

7. Existing Flooring Treatment- Failed: In case, if flooring treatment is proposed on existing failed flooring treatment / for renovation, it is recommended to prepare surface for the required Surface profile similarly to Concrete Surface Profile, or remove it completely or contact Manufacturer for specification.

8. Crack Treatment:  Cracks commonly occur due to settlement of base, vibration of the structure or insufficient detailing of the movement/construction joints. Static cracks shall be cleaned and filled using EP 320, concrete crack repair epoxy, Solvent-free, Low Viscosity Epoxy Resin.

8. Damaged control / contraction joints: Control/contraction joints are provided in large sized floor area to accommodate the movement of the slab. Forklift movement across the joint shoulders tend to chip of any small imperfections. These areas tend to become wider & deeper rapidly and become a potential risk. Failed joints allow liquid contaminants and dust to accumulate and reach the concrete matrix increasing the risk of floor deterioration.  Hence joint treatment should be addressed quickly to prevent increased repairs. Edge can be repaired using A 45, Rapid Drying and Hardening Internal Repair Mortar and joint gap shall be filled using SU 10, single component flexible PU sealant or by R 50 CP, 2K urethane.

Surface preparation can save time and money as well as substantially reducing the possibility of Industrial Flooring treatment failure and costly re-works.

ARDEX ENDURA ACADEMY

Our industry, like any other, requires on-going training to keep up with the changes in legislation/standards and materials. Our purpose-built training facility enables us to offer a range of demonstrations and seminars that can be tailored to your specific needs, ensuring total confidence in the specification and subsequent on-site application. The academy allows you to learn about new technologies including ‘Industry best practices for Tiling, Waterproofing, Concrete Repair and Flooring’ along with Technical guidance and product information.

For the latest and most up to date information and advice, visit the ARDEXENDURAacademy centres across India (Bangalore, Mumbai, Ahmedabad, Delhi, etc.,). For Flooring Contractors and applicators committed to providing a high level of workmanship, ARDEX ENDURA helps them to increase both their professionalism and productivity.

For more details about ARDEX ENDURA’s Polyurethane Flooring Products, Epoxy Flooring Products and Cementitious Flooring Product, visit: www.ardexendura.com

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