Services
FLOORING APPLICATION
GRANDFLOR LEVELLER 10Cementitious self leveling, self smoothing compound
SCOPE
This section covers the standard requirements for Flooring Application using GRANDFLOR LEVELLER 10 (Cementitious self leveling, self smoothing compound).
General
Correct evaluation and subsequent preparation of the existing concrete floor is required to achieve a good performance of the finished floor system. This to both new construction and refurbishment work.
Assessment of existing floor
The first step in the installation of GRANDFLOR LEVELLER 10 products is to carry out a detailed survey of the existing floor and an assessment of the service conditions, which will determine the performance characteristics required of the new floor. Any signs of damage, contamination or other defects should be noted and corrected.
Floor strength
A weak substrate can lead to floor topping failure usually due to impact damage or abrasion.
Floor strength should be at least 3,000 psi (210 N/mm2). New concrete floors must normally be at least 14 days old prior to application of GRANDFLOR LEVELLER 10 flooring systems.
Floor strength should be at least 3,000 psi (210 N/mm2). New concrete floors must normally be at least 14 days old prior to application of GRANDFLOR LEVELLER 10 flooring systems.
1) Surface Preparation Works
1.1 The substrate must be clean, sound and free from dust, oil, grease or surface contaminants.
1.2 Removed any cement laitance, formwork traces and loosely bonded particles.
1.3 New concrete should be at least 14 days before application of GRANDFLOR LEVELLER 10.
1.4 Large cracks or holes must be filled using equal volumes of GRANDFLOR LEVELLER 10 and clean sand to trowellable mortar.
2) Priming
2.1 All surfaces should be sealed prior to application of GRANDFLOR LEVELLER 10.
2.2 Prime the surface with GRANDCRETE ACR, 1:1 water / Grandcrete ACR mixture by volume. The primer should be allowed to dry to form an impervious barrier between substrate and the GRANDFLOR LEVELLER 10 to improve bond and prevent release of air from the substrate.
2.3 The second priming of the floor is carried out when the first priming coat is dry.
2.4 If the floor is extremely porous it may be necessary to prime a third time with the primer diluted at 1:1 ratio with clean water.
Note: The primer must be well brushed out to avoid ponding of primer because this can lead to failure at the bond line.
2.5 Once the primer has dried (film formation can be seen on the surface), GRANDFLOR LEVELLER 10 product can be applied to the floor.
3) Mixing
3.1 Mix 25 kg bag of GRANDFLOR LEVELLER 10 with 6.0 to 6.5 liters of clean water.
3.2 Pour the water into a clean mixing vessel. Add the powder slowly to the water while mixing continuously with a heavy duty drill fitted with purpose made paddle.
3.3 Continue mixing for at least 3 minutes until a creamy consistency is obtained.
3.4 Do not mix more GRANDFLOR LEVELLER 10 that can be laid in about 15 minutes but ensure that the next mix is ready so that pouring can be continued until the whole area to be applied is complete.
3.5 No additional water above the normal 6.0 to 6.5 liters should be used.
3.6 Ensure that sufficient labor is available to enable continuous mixing and pouring.
4) Application
4.1 Application by pump
4.1.1 Installation should start at a corner with the operator walking slowly at constant rate across the floor, allowing material to flow from the discharge hose.
4.1.2 The hose should be positioned so that the material discharges marginally into the material laid previously.
4.1.3 The maximum bay width which can be applied depends on the temperature, type of mixer pump and the thin flooring products used.
4.1.4 Roll surface with spiked roller to aid air release and leveling. This procedure which aid air release should be carried out immediately after material has been discharged onto the floor. It also provides the final smoothing of the surface layer.
4.2 Application by hand
4.2.1 Pour the mixed material into the dry primed surface immediately, spread out with trowel and then allow to flow smooth.
4.2.2 Finish by drawing across the surface of the previously laid material with a spiked roller to aid air release and leveling. Do not over roll. Best results are achieved when the pouring and leveling is a continuous process.
4.2.3 The required thickness must be achieved in one application.
Caution:
1. Do not attempt to float the setting surface.
2. If a mix stiffens before it has been spread, it must be discarded. Do NOT attempt to remix with water.
2. If a mix stiffens before it has been spread, it must be discarded. Do NOT attempt to remix with water.
5) Curing and Protection
5.1 Curing should be carried out in conditions of high ambient temperatures, direct sunlight, drying winds, etc. Freshly hardened surfaces should be covered with polythene sheets for at least two days.
GRANDFLOR EFCEpoxy Floor Coating
SCOPE
This section covers the standard requirements for Flooring Application using GRANDFLOR EFC ( Epoxy Floor Coating).
General
Correct evaluation and subsequent preparation of the existing concrete floor is required to achieve a good performance of the finished floor system. This is to both new construction and refurbishment work.
Assessment of existing floor
The first step in the installation of GRANDFLOR EFC product is to carry out a detailed survey of the existing floor and an assessment of the service conditions, which will determine the performance characteristics required of the new floor. Any signs of damage, contamination or other defects should be noted and corrected.
Floor strength
A weak substrate can lead to floor topping failure usually due to impact damage or abrasion or delamination.
Floor strength should be at least 3,000 psi (210 N/mm2).
New concrete floors must normally be at least 14 days old prior to application of GRANDFLOR EFC flooring systems.
1) Surface Preparation Works
The long term durability of any resin floor system is determined by the adhesive bond achieved between the flooring material and the substrate. It is most important therefore that the substrates are correctly prepared prior to application.
1.1 The substrate must be clean, sound and free from dust, oil, grease or surface contaminants.
1.2 Removed any cement laitance, formwork traces and loosely bonded particles. For removing laitance on the substrate, application of Grand Acid Etch must be used in either one or two application depending on the saturation of oil on the substrate. Old coatings should be removed by any mechanical means either by grinding or scabbler to expose good concrete surface profile.
1.3 As final cleaning agent, use Grand Surface Cleaning Agent wipe to ensure a clean and dust-free before the application of Grandflor EFC.
1.4 All dust and debris should be removed prior to application of the product.
1.5 Large cracks or holes must be filled using GRANDFIX EPOXY REPAIR MORTAR or EPOXY INJECTION RESIN whichever is applicable on crack condition.
1.6 For flooring with pinholes and uneven surfaces, patch the area with Grand Epobond Putty.
2) Product Application
2.1a Apply 1-coat of GRAND EPOPRIME CLEAR – high build epoxy resin base primer into the dry and clean substrate. Coverage is about 12 to 15 sq.m. per gal-set depending on the porosity of the substrate. It can be applied by brush, roller, steel trowel, conventional spray or airless spray equipment.
2.2b GRAND EPOPRIME CLEAR serve two important functions:
1. To provide a good adhesive bond of the GRANDFLOR EFC to the substrate.
2. To seal the concrete surface and thus minimize problems associated with entrapped air in the substrate, migrating into the GRANDFLOR EFC itself and creating blisters.
2. To seal the concrete surface and thus minimize problems associated with entrapped air in the substrate, migrating into the GRANDFLOR EFC itself and creating blisters.
2.2 A recommendation for major putty application may be applied to the whole area to improve surface flatness.
2.3 Re-prime the surface with epoxy putty then wait until the putty has fully cured. It is necessary to sand lightly to provide toehold for the next application.
2.4 GRANDFLOR EFC can be applied by brush, roller, conventional spray or by airless spray equipment at the rate of 20-25 sqm per gallon per coat. To paint over a hundred previous coat, it is necessary to sand it lightly to provide a good toehold for the next coat.
2.5 For the conventional spraying, GRAND EPOXY REDUCER may be added to the mixture 10 – 15% by volume. Allow 10-15 minutes induction time before application.
3) Mixing
3.1 For Grand Epoprime Clear – stir the content using mixing rod before application for 1 to 2 minutes.
3.2 For Grandflor EFC – use slow speed mixing drill fitted with spiral paddle or mixing rod, but be sure homogeneous mixture is observed.
4) Health and Safety
4.1 During application of Grandflor EFC, make sure that the area is totally sealed since its smell is attractive to flying insects yet is ventilated enough to avoid prolong breathing its vapor.
4.2 Keep containers well closely tight. Wear necessary protection to avoid contact with skin.
4.3 In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.
5) Curing Time
5.1 Tack to free time – four hours @25 degree centigrade
5.2 Curing time : 24 (twenty four) hours – under normal condition
5.3 Could accommodate pedestrian traffic after twenty four (24) hours.
GRANDFLOR PU MORTARTrowel Applied Polyurethane Mortar Topping
SCOPE
This section covers the standard requirements for Flooring Application using GRANDFLOR PU MORTAR (Trowel Applied Polyurethane Mortar Topping
General
Correct evaluation and subsequent preparation of the existing concrete floor is required to achieve a good performance of the finished floor system. This is for both new construction and refurbishment work.
Assessment of existing floor
The first step in the installation of GRANDFLOR PU MORTAR products is to carry out a detailed survey of the existing floor and an assessment of the service conditions, which will determine the performance characteristics required of the new floor. Any signs of damage, contamination or other defects should be noted and corrected.
Floor strength
A weak substrate can lead to floor topping failure usually due to impact damage or abrasion or delamination.
Floor strength should be at least 3,000 psi (210 N/mm2).
New concrete floors must normally be at least 14 days old prior to application of GRANDFLOR PU MORTAR flooring systems.
Floor strength should be at least 3,000 psi (210 N/mm2).
New concrete floors must normally be at least 14 days old prior to application of GRANDFLOR PU MORTAR flooring systems.
1) Surface Preparation Works
1.1 The substrate must be clean, sound and free from dust, oil, grease or surface contaminants.
1.2 Removed any cement laitance, formwork traces and loosely bonded particles.
1.3 New concrete should be at least 14 days before application of GRANDFLOR PU MORTAR.
1.4 Large cracks or holes must be filled using GRANDFIX EPOXY REPAIR MORTAR
- Providing the concrete substrate is of adequate strength, sound and free of major defects, the following surface preparation techniques are acceptable.
The use of chemical preparation alone is not recommended. Acid etching should be used in conjunction with high pressure water and must entirely removed the top surface layer of laitance and exposed the sand in the concrete. Chemical degreasers should only be used in areas with oil and grease contamination prior to a full program of mechanical preparation.
Captive blasting – is the fastest and cleanest technique available. Its principle advantage is the removal of the blasting medium during the surface preparation stage, which is often a vital pre-requisite in preparing surfaces adjacent to other working areas.
Mechanical scarifying – mechanical scarifying machines can be used. The floor will need to be vacuumed following the use of the machine to remove the dust and debris left behind. The mechanical scarifying type machine will have tha advantage of removing high spots on rough floors which may be beyond the ability of a captive blasting machine.
2) Repairs
2.1 It will often be necessary to repair areas of the concrete substrate prior to application and this is preferably done following the substrate preparation.
2.2 It is vital that cracks, spalls and areas of unsound concrete be repaired before applying GRANDFLOR PU MORTAR flooring, preferably by employing epoxy based repair compounds such as GRANDFIX EPOXY REPAIR MORTAR.
2.3 Polyester based material must NOT be used and should cementitious based repairs be used, sufficient time must be allowed before over-coating to allow for proper curing (one to seven days is typical).
3) Priming
Once the surface has been fully repaired, it must be primed using GRAND EPOPRIME CLEAR, a two component epoxy primer. The GRAND EPOPRIME CLEAR serves two functions:
3.1 To provide a good adhesive bond of the GRANDFLOR EPX SL to the substrate.
3.2 To seal the concrete surface and thus minimize problems associated with entrapped air in the substrate, migrating into the GRANDFLOR PU MORTAR itself and creating blisters.
3.3 The primer must be applied approximately, 2 – 8 hours before the GRANDFLOR PU MORTAR application, to allow it to dry. This is usually accomplished by an overnight drying period. The PU MORTAR must be applied within 48 hours of priming.
Primer Application
Thoroughly mix the entire contents of the GRAND EPOPRIME CLEAR and apply to the dry substrate, using a roller or brush, making sure that no dry areas are visible on completion.
Do not apply thickly or allow to puddle.
If any area appears to absorb the primer rapidly, re-prime those areas immediately, thus avoiding the need to re-prime the next day with consequent loss of time.
Thoroughly mix the entire contents of the GRAND EPOPRIME CLEAR and apply to the dry substrate, using a roller or brush, making sure that no dry areas are visible on completion.
Do not apply thickly or allow to puddle.
If any area appears to absorb the primer rapidly, re-prime those areas immediately, thus avoiding the need to re-prime the next day with consequent loss of time.
4) Mixing
4.1 Two types of mixers can used with the GRANDFLOR PU MORTAR range of products depending on the size of the job:
- A slow speed drill fitted with an spiral paddle. This technique is suitable for single kit of mixing of GRANDFLOR PU MORTAR, but is not ideally suited to double kit mixing or bulk application techniques.
- A mortar mixer or paddle mixer (blades revolve, pan stationary) is suitable for large volume pours.
- A mortar mixer or paddle mixer (blades revolve, pan stationary) is suitable for large volume pours.
4.2 In all cases, it is recommended that the base and hardener are mixed together prior to the addition of the aggregates.
4.3 Ensure that the sides of the containers of these liquids are scraped down with a spatula.
4.4 When the liquid mix is uniformly mixed (approximately 1 minute), add the aggregates.
4.5 Mixing using a slow speed drill and paddle will usually take 3 – 5 minutes.
4.6 Ensure that the material is mixed as the applicator requires it. DO NOT mix material and leave it standing while waiting for the applicator to level off the previous batch.
4.7 When mixing is completed for the day, clean all equipments with GRAND SOLVENT 100.
5) Application
5.1 Pour the mixed material onto the floor.
5.2 The mixed material should be placed on the floor in quantities that the applicator can handle comfortably. If too much material is placed on the floor, there is danger that:
- The material will be spread too thickly.
- The material will be spread too quickly leaving marks that will not roll out, particularly at the interface, between the wet edge and fresh material.
- Aggregate in GRANDFLOR PU MORTAR will settle out before the applicator has had an opportunity to spread it to the correct thickness.
- Aggregate in GRANDFLOR PU MORTAR will settle out before the applicator has had an opportunity to spread it to the correct thickness.
5.3 The fresh material should be placed as closely as possible to the wet edge and applied using a flat edged trowel ensuring it links continuously to the previously applied material.
5.4 The material should not be overworked as this may result in the transfer of resin away from high spots leaving aggregate showing through the top surface.
5.5 The applicators should, immediately after spreading out material, check the finished appearance of the floor for defects, such as low spots and deep trowel marks, to allow the trowel man ample time to rectify the problem.
5.6 The rate of application will vary depending on the substrate, mixing technique used, and number of men on the job.
6) Spiked Rolling
Rolling of the GRANDFLOR PU MORTAR flooring is carried out for the following reasons:
- To initiate segregation of the aggregate and resin components resulting in settlement of the aggregate and the formation of resin rich upper surface.
- To remove blemished such as trowel marks.
- To release entrapped air.
- It is vital that rolling is carried out to avoid the risk of air entrapment, which in turn can lead to blistering. The application team must pay particular attention to this process since the final appearance is dependent on this.
- To remove blemished such as trowel marks.
- To release entrapped air.
- It is vital that rolling is carried out to avoid the risk of air entrapment, which in turn can lead to blistering. The application team must pay particular attention to this process since the final appearance is dependent on this.
The rolling technique used is as follows:
6.1 GRANDFLOR PU MORTAR should be rolled heavily immediately after applying using a spiked roller, ensuring that the roller penetrates deeply into the material.
6.2 Rolling should be carried out at right angles to the direction of the screeding operation and should follow the same path back and forth.
6.3 Spiked shoes must be worn during rolling process.
6.4 The next line of rolling must overlap the first by half the roller width. A second light rolling at right angles to the first rolling should be carried out.
6.5 With light rolling, let the roller glide under its own weight and do not push into the topping since this will disturb the aggregate layer.
6.6 A third light rolling should be carried out only if air bubbles continue to appear on the surface.
7) General Procedures
7.1 Whenever possible ensure that application is carried out in a closed environment free from excessive air movement and large or sudden temperature change.
7.2 Exposure of the fresh floor surface to direct sunlight is not desirable during the first 24 hours.
7.3 On jobs where it is not possible to complete a floor in one day, a day joint will have to be formed. Ideally, it is best to stop at an expansion joint, along a line of columns or other floor structure. The site layout will dictate the choice of stopping points. The following method of forming a day joint is recommended:
- Place a 2 inch wide strip of masking tape on the substrate and finish the application process across the strip. After 2 -4 hours peel the strip off the floor, leaving a straight line across the face of the GRANDFLOR PU MORTAR.
- A square edge must be cut in the hardened material using a disc cutter just behind the finished edge to give a clean face to butt to. Before starting to apply further GRANDFLOR PU MORTAR material against a previously formed joint face, mask a strip 2 – 3 feet wide back from the joint edge to prevent fresh resin being splattered onto the existing GRANDFLOR PU MORTAR. Again, when rolling has finished in the area of the joint, remove the masking tape before the GRANDFLOR PU MORTAR gels.
8) Troubleshooting
Substrate Preparation
If there is any reason to suspect that the floor to be covered suffers from dampness or excess moisture content, carry out checks before work starts. A moisture content above 5% is not permissible.
