Cement-Based Flooring SystemsThe Good, Bad and the Ugly

H. Peter Golter, PE

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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

Brief Overview of Concrete

• Indestructible, Right?

• How many types of concrete are there?

• What are they?

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What are Floor Resurfacers?

* Referencing ACI 116R-00 Cement and Concrete Terminology

Toppings*

A layer of concrete or mortar placed to form a traffic bearing floor surface on a concrete base

Underlayments

A thin capping of existing concrete, wood or primed metal floors to provide a surface suitable to receive floor covering or coating

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What are Floor Resurfacers?

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

ScreedsSkim Coats

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Why are Floor Resurfacers Necessary?

Requirements for concrete contractors

To correct or modify existing jobsite conditions

Requirements for flooring manufacturers

+/- 1/4” in 10 lineal feet +/- 1/16” in 10 lineal feet

There are different industry standards for the different tradesExample:

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Advantages of Floor Resurfacers

• 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)

Level a floor within required specification

Wood flooring

Self-leveling underlaymentAdhesive

Concrete substrate

Primer/admixture (when required)

Patching material

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Commercial Applications

• Offices

• Educational facilities

• Municipalities

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Residential Applications

• High rises/condominiums

• Single-family homes

• Townhomes

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Healthcare Applications

• Medical office buildings

• Outpatient facilities

• Assisted living facilities

• Hospitals

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Retail Applications

• Restaurants

• Malls/shopping centers

• Big box and shoe box

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Industrial Applications

• Food processing

• Chemical

• Pulp and paper

• Manufacturing

• Warehouse

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What Technologies are Available Today?

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Available Technologies

• Gypsum: least expensive, most common material

• Portland-based: moderately priced; wide range of applications

• Modified Portland:

– Polymer: Adds density and flexural capabilities

– Pozzolans: Densifiers and increases ultimate strength

• Self-drying cements: Extremely quick return to service due to rapid internal hydration

• Polymers (resins): Very expensive, engineered plastics; typically vapor barriers

Price

High

Low

Performance

Low High

Gypsum

Portland-based

Modified Portland – pozzolans

Modified Portland – polymer

Self-drying cements

Polymers (resins)

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Advantages of Floor Resurfacers

• 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

Support the traffic load

NOTE: Contact the manufacturer for specific material or product recommendations

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Advantages of Floor Resurfacers

• Conventional concrete is 3,000-4,000 psi compressive strength

• Engineered materials with performances up to and exceeding 10,000 psi for greater longevity and reduced maintenance costs

Abrasion resistance

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Who is Typically Involved in These Projects?

What does a winning team look like?

Owner Architect

EngineerContractor/Specialty Contractor

ManufacturerSupplier

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What is the #1 Priority for Any Property Owner?

VALUE!

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Perception versus Reality

• Factory-fabricated samples for system selection

• Insist on representative jobsite mockups

• Use jobsite mockups and field flow tests as quality assurance

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What Happens with Moisture in the Concrete?

Concrete and MoistureConcrete 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

Don’t install until it passes

Wait for the concrete to dry

Accept a sign off from the general contractor!?

When Moisture Testing Fails…

Modes of Concrete Floor Moisture Failures

Adhesive breakdownDisbondingAlkali attackMicrobiological activityStainingEfflorescenceCondensationCurling

Adhesive Breakdown

Disbonding

Adhesive Oozing

Mold

Efflorescence

Moisture in New ConcreteNew meaning to embedded steel

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How Fast is – Fast Track Construction?

Fast Track Construction Rehab a Floor Over the Weekend

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Preparing the Floor

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Application of PrimerExisting Concrete and Epoxy Coating

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1-Comp.Primer

Attention to DetailsWeigh out the Pigments by Batch

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Delivery Method

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Gauge Rake – Proper DepthSmoother – Get the “Glass” Finish

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Protect the surrounding areaFinal Clean-up

Integral Color & Sealed – Before and After

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Finished Floor

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Structural Deficiency – Floors Out of Spec

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?

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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

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Repair Material Staged on Job

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All floors marked to finish elevation

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All floors marked to finish elevation

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Surface Preparation - Shotblasting

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Application of Primer

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Verifying the Finish Elevation

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Water Source and Pump

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Getting Ready to Pump

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Pump Operator

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Mixed Material Going into Pump

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Material being placed and finished

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Floor is now level!!!

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Finished Cured Floor

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What is the Size of the Project?

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Bldg#2 - So what went wrong?

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Finished Installations

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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)

Cement MasonsA Wear Topping Stained and Polished

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LA RestaurantStained and Polished

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Finished Installations Done Correctly

• Screeds

• Self levelers

• What is the primary function?

– Utility (warehouse floors)

– Decorative (commercial floors)

Toppings

Finished Floors

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Finished Installations Done Correctly

• Large body tile or stone placed tight together

• Slope to drain

• ADA compliance

Screeds (dry pack and wet mix)

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Examples of Finished Installations

• Installation consisting of

− Screed floor (mud bed)

− Polymer modified thin set

− Porcelain body tile

− Polymer modified grout

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Examples of Finished Installations

• Installation consisting of

− Skim coat

− Carpet adhesive

− Carpet tiles

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Examples of Finished Installations

• Installation consisting of

− Self-leveling underlayment

− Urethane wood adhesive

− Pre-finished engineered wood

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Examples of Finished Installations

• Installation consisting of

− Self-leveling underlayment

− Mastic

− VCT

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THANK YOU FOR YOUR TIME!

QUESTIONS?

www.prospec.com800.334.0784