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 December, : 1.LYONS MANUFACTURING, INC., 2.ARDEX Americas, 3.CTS Cement Manufacturing Corporation.
Link to KDOCEL
What Is Self-Leveling Material?
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.
Uses of Self-Leveling Material
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.
Principle of Self-Leveling Material
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:
1. Preparation Before Construction
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.
2. Preparation of the Substrate
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.
3. Primer Application
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.
4. Placing Self-Leveling Material
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.
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Details are matched to the ink or level point using a trowel. Finish by pouring gently, quickly, and evenly.
5. Curing and Drying
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.
6. Finish Inspection and Rework
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.
Types of Self-Leveling Materials
Self-levelling materials can be classified into two categories: gypsum-based and cement-based.
1. Gypsum-Based Self-Leveling Material
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.
2. Cement-Based Self-Leveling Material
Many cementitious materials feature high strength, and some can be used externally. After curing, they are also characterized by their resistance to water.
Self-leveling concrete products consists of a blend of Portland and/or calcium aluminate cements, inorganic aggregates, co-polymers, and chemical modifiers, which form a flowable, self-leveling compound for leveling interior or exterior substrates. These component form a high compressive strength and flowable cementitious compound, resulting in a flat-surface that accepts ceramic tiles, natural stone, hardwood flooring, VCT, linoleum or concrete overlays.
Self-leveling concrete products sold today are mixed with water only; no liquid acrylic-latex additive is required. The dry re-dispersible co-polymers in the formulations provide improved bond strength with various substrates, Self-leveling concrete products are formulated with proprietary copolymers and cements, which provide very high compressive strengths within a very short period of time after they are installed. The high compressive values results in a floor assembly that consistently passes all 14 cycles on an ASTM C627 Robinson Floor test for most applications. This &#;Extra Heavy Duty; rating for the finished floor is crucial for floors that are subjected to heavy floor traffic and large equipment such as scissor lifts and pallet jacks. Alternative self-leveling applications, such as those over hydronic tubing or electric radiant heat systems. Installations over wood joist /plywood sub floor installations can provide a light commercial to a standard residential service depending upon the specific assembly detail.
The versatility of cement based self-levelers allows for self-leveling concrete pours that can be applied from 1/4&#; to 1.5&#; in a single pass. Self-leveling concrete products can also be feather-edged to transition other floor finishes. Allowable thickness vary depending upon the specific formulation. Certain proprietary formulations are available that provide an extended set for pumping. These are designed for use in high ambient temperature conditions, or over large spans when more time to float the material is required. The cure rates of self leveling concrete materials provide for a fast setting underlayment or overlayment that can accept tiles or hardwood floors in as little as 4 hours and 14-18 hours for resilient flooring or concrete microtoppings after the concrete is in place. This helps to minimize project downtime and allows the work schedule to proceed more expeditiously.
CLICK HERE to watch the complete installation process of self-leveling concrete floor.
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