Wear Resistance Flooring

Introduction: 

 Floor hardener (Silicon carbide wear-resistance floor) includes nonmetal and metal floor hardener; both of the hardeners are composed by nonmetal or metal aggregates with standardized Portland cement and other admixtures, can be directly put into use after opening the pocket.
Advantage: Very high strength and wear resistance, dust proof, oil proofing, can remarkably reduce working period.

Scope of application:

Industrial floor where requires wear resistance and dust-proof. For example, warehouse, dock, factory, park, maintenance shop, garage, etc.
Color: cement nature, grey, green or red.
Moh’s hardness: Nonmetal type: 7~8; Metal type: 8;
Strength of 28days: Nonmetal type: 80MPa; Metal type: 91MPa;
Fit for foot traffic after: 48-72 hours;
Fit for light traffic: 7-10days;
Fit for full traffic: after 28days.

 
Construction of wear resistance floor:

 
A) Construction equipments for wear resistance floor

(1) Tools aim at bleeding: Rubber tube or vacuum lift pump;
(2) Flatting outlet pipe: Ф150 steel tube which fills sands in the middle; it is at least 500mm longer than the width of floor mold; setting rotatable ring-pull on both ends;
(3) Power trowel: the chassis is four steel disc, which can press polish floor surface by adjusting the angle of steel disc (small angle for soft surface and big angle for hard surface);
(4) Flat keel rubber shoes:  worn after initial set of concrete; water-proof paper shoes or water-proof paper bag be used when surface press polishing;

B) Construction organization of wear resistance floor:

Reference for 500sqm/day: exclusive of the staff of concrete pouring work, need the following labor: 3persons for concrete leveling, 3 for material transporting; 3 for broadcasting, 3 for power trowel, 3 for repairing. In accordance with the above standard, continuous construction can finish 2000sqm/day if applied 6~7 power trowels and relevant staff;

C) Preparation for wear resistance floor:

1. Compact the sand-gravel filling layer underground by roller;
2. Set steel formwork or U-steel formwork in accordance with designed elevation, detect elevation at any time with level, adjust any deviation by wedge;
3. Set joint seams through vertical and horizontal axis points according to specification requirements;
4. The maximum particle size of gravel is ≤30mm, concrete water cement ratio and slump shall be as small as possible;
5. Concrete must be no inferior to C25, and the slump on site is in the range of 75-100mm.

D) Construction process of wear resistance floor:

1. Setting-out/ Layout of finishing surface;
Set schedule concrete pouring thickness in construction area with level according to building structure reference ink mark，for example, the line of wall surface+50cm, setting horizontal elevation sign, and double check to control maximum deviation in range of 3-5mm;
2. Concrete pouring:
2.1 Watering the substrate to be damp before concrete pouring. Control water- cement ratio and slump to control bleeding, the method of unloading commercial concrete shall be down-spouting and manual, other than pumping;
2.2 Pouring concrete to designed elevation in a time as far as possible, supplement concrete slurry and vibrate for those local places where be short of specified elevation, repair mortar is strictly prohibited. Use plating vibrator to vibrate and steel roller to roll thresh thrash, slap with wood trowel to column and corner. After striking, the concrete slurry should be thicker at least 3mm than the surface.
2.3 After pouring concrete, remove the bleeding water with rubber tube or vacuum equipment, repeat the work , then begin the construction of hardener flooring. During middle period of wear resistance flooring, the staff should wear flat keel rubber shoes onto the construction area, during the later period, should wear water-proof paper shoes.
3. Broadcast wear resistance material for the 1st time and floating:
The timing of broadcast will be changed with climate, temperature, concrete composition, and so on. Step on the floor, if trap in about 5mm, then can broadcast the wear resistance materials for the 1st time.
3.1 Moisture of those places where near wall, column, door, forms and other side boundaries will lose sooner than other places, so broadcasting should be done at these places prior.
3.2  The ratio of broadcasting for the first time is about 2/3 to the total amount.
4. Broadcasting for the 2nd time and trowelling:
4.1 Before broadcasting, measure the levelness with straight-edge, then adjust the amount to the uneven place, the direction of the 2nd time broadcasting should be across to that of the 1st time.
4.2 The amount of broadcasting for the 2nd time is the rest 1/3, trowelling immediately after broadcasting, at least twice the trowelling work. Treat the corners with wood float.
5. Curing of wear resistance floor:
Spray curing agent 5-6 hours after the construction of wear resistance flooring, the consumption amount is approx. 0.2l/m2, or cover plastic film to prevent cracking.
6. Form removal can be carried out after 24 hours, but be careful not to hurt the floor edges.
7. Sawn cut joints in 5-7days after completing the pouring works to prevent irregular cracks. The interval between joints should be 6-8m (usually according to intercolumniation). The cutting works should be according to the snap-line to assure the straightness. The deepness should be at least 1/3 thickness of the concrete slab.
8. Grouting joints: Before the use of floor, the sawn cut joints should be grouting with elastic resin materials.