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Cement-Based Flooring Systems The Good, Bad and the Ugly H. Peter Golter, PE Presentation Agenda • Brief Overview of Concrete • Brief Overview of Floor Rehabilitation/Resurfacing • Project Overview – Moisture Related Problems • Project Overview – Fast Track Construction • Project Overview – Structural Deficiency/Floors Out-of-spec • Recap – Review Successful Finish Floor Installations 2 Brief Overview of Concrete • Indestructible, Right? • How many types of concrete are there? • What are they? 3 What are Floor Resurfacers? Toppings* Underlayments A layer of concrete or mortar placed to form a traffic bearing floor surface on a concrete base A thin capping of existing concrete, wood or primed metal floors to provide a surface suitable to receive floor covering or coating * Referencing ACI 116R-00 Cement and Concrete Terminology 4 What are Floor Resurfacers? Skim Coats Screeds A thin build of material used to cover and level defects in concrete, vinyl, tile, metal, wood and other subfloors To strike off a trowel grade, cementitious material to fill in or level rough concrete surfaces prior to the installation of floor coverings 5 Why are Floor Resurfacers Necessary? To correct or modify existing jobsite conditions There are different industry standards for the different trades Example: Requirements for concrete contractors Requirements for flooring manufacturers +/- 1/4” in 10 lineal feet +/- 1/16” in 10 lineal feet 6 Advantages of Floor Resurfacers Level a floor within required specification Wood flooring • With floor resurfacing products, installers can meet any flooring system requirement • The following floor finishes require smooth floors – Vinyl sheet goods – Wood – Thin coatings – Stains – Sealers • Units of measurement: – +/- “x" inches/10 feet – Flatness (Ff) – Levelness (Fl) Self-leveling underlayment Adhesive Primer/admixture (when required) Patching material Concrete substrate 7 Commercial Applications • Offices • Educational facilities • Municipalities 8 Residential Applications • High rises/condominiums • Single-family homes • Townhomes 9 Healthcare Applications • Medical office buildings • Outpatient facilities • Assisted living facilities • Hospitals 10 Retail Applications • Restaurants • Malls/shopping centers • Big box and shoe box 11 Industrial Applications • Food processing • Chemical • Pulp and paper • Manufacturing • Warehouse 12 What Technologies are Available Today? 13 Available Technologies High Polymers (resins) • Portland-based: moderately priced; wide range of applications Self-drying cements • Modified Portland: Modified Portland – polymer Price • Gypsum: least expensive, most common material – Polymer: Adds density and flexural capabilities – Pozzolans: Densifiers and increases ultimate strength Modified Portland – pozzolans • Self-drying cements: Extremely quick return to service due to rapid internal hydration Portlandbased • Polymers (resins): Very expensive, engineered plastics; typically vapor barriers Gypsum Low Low High Performance 14 Advantages of Floor Resurfacers Support the traffic load • A variety of products are engineered for longevity and durability for the following traffic conditions: – Residential foot traffic – Commercial foot traffic – Vehicular traffic – Industrial hard wheel traffic – Steel wheel traffic NOTE: Contact the manufacturer for specific material or product recommendations 15 Advantages of Floor Resurfacers Abrasion resistance • Conventional concrete is 3,0004,000 psi compressive strength • Engineered materials with performances up to and exceeding 10,000 psi for greater longevity and reduced maintenance costs 16 Who is Typically Involved in These Projects? What does a winning team look like? Owner Architect Contractor/ Specialty Contractor Engineer Supplier Manufacturer 17 What is the #1 Priority for Any Property Owner? VALUE! 18 Perception versus Reality • Factory-fabricated samples for system selection • Insist on representative jobsite mockups • Use jobsite mockups and field flow tests as quality assurance 19 What Happens with Moisture in the Concrete? 20 Concrete and Moisture Every flooring manufacturer has specific requirements regarding the moisture content of concrete to receive their flooring. These requirements must be made known to the specifier, architect, general contractor and flooring specialist. • Setting and Meeting Expectations When Moisture Testing Fails… Don’t install until it passes Wait for the concrete to dry Accept a sign off from the general contractor!? Modes of Concrete Floor Moisture Failures Adhesive breakdown Disbonding Alkali attack Microbiological activity Staining Efflorescence Condensation Curling Adhesive Breakdown Disbonding Adhesive Oozing Mold Efflorescence Moisture in New Concrete New meaning to embedded steel How Fast is – Fast Track Construction? 30 Fast Track Construction Rehab a Floor Over the Weekend 31 Preparing the Floor 32 Application of Primer Existing Concrete and Epoxy Coating 1-Comp. Primer 33 Attention to Details Weigh out the Pigments by Batch 34 Delivery Method 35 Gauge Rake – Proper Depth Smoother – Get the “Glass” Finish 36 Protect the surrounding area Final Clean-up Integral Color & Sealed – Before and After 37 Finished Floor 38 Structural Deficiency – Floors Out of Spec 39 What Went Wrong? • • • • Structure was “Value Engineered” Construction was awarded to “Low Bidder” Bonus to GC to complete the project early Project Schedule was compressed • Does “Pisa” come to mind? 40 What Is The Solution? • Analysis indicates dead loads are a major consideration. • Design Criteria: – Level the floors. Some areas 3+ inches – Maximum 60#/Cubic Foot for repair material – Material must be at least 3,500 psi for finish flooring manufacturer’s to warrant their product – Quick return to service, next day trades are on it 41 Repair Material Staged on Job 42 All floors marked to finish elevation 43 All floors marked to finish elevation 44 Surface Preparation - Shotblasting 45 Application of Primer 46 Verifying the Finish Elevation 47 Water Source and Pump 48 Getting Ready to Pump 49 Pump Operator 50 Mixed Material Going into Pump 51 Material being placed and finished 52 Floor is now level!!! 53 Finished Cured Floor 54 What is the Size of the Project? 55 Bldg#2 - So what went wrong? 56 Finished Installations 57 Finished Installations Gone Wrong • Wavy floors (i.e., sheet goods, epoxy coatings) • Hollow spots under wood floors • Transitions to different finished flooring materials (i.e., carpet, wood, sheet goods and tile) 58 Cement Masons A Wear Topping Stained and Polished 59 LA Restaurant Stained and Polished 60 Finished Installations Done Correctly Toppings • Screeds • Self levelers • What is the primary function? – Utility (warehouse floors) – Decorative (commercial floors) 61 Finished Floors 62 Finished Installations Done Correctly Screeds (dry pack and wet mix) • Large body tile or stone placed tight together • Slope to drain • ADA compliance 63 Examples of Finished Installations • Installation consisting of − Screed floor (mud bed) − Polymer modified thin set − Porcelain body tile − Polymer modified grout 64 Examples of Finished Installations • Installation consisting of − Skim coat − Carpet adhesive − Carpet tiles 65 Examples of Finished Installations • Installation consisting of − Self-leveling underlayment − Urethane wood adhesive − Pre-finished engineered wood 66 Examples of Finished Installations • Installation consisting of − Self-leveling underlayment − Mastic − VCT 67 THANK YOU FOR YOUR TIME! QUESTIONS? www.prospec.com 800.334.0784 68