the choice of professionals ™ seth pevarnik manager of technical service

The Choice of The Choice of ProfessionalsProfessionals™™

Seth PevarnikManager of Technical Service

Self-leveling & Patching Self-leveling & Patching MaterialsMaterials

Categories of flooring failure.Categories of flooring failure.

Proper methods of substrate preparation.Proper methods of substrate preparation.

Selection of Self-leveling & Patching Selection of Self-leveling & Patching

materials.materials.

Failure modes for Self-leveling & Patching Failure modes for Self-leveling & Patching

materials.materials.

CELL PHONES

Industry Studies

WHY FLOORS FAIL . . .WHY FLOORS FAIL . . .

85% OF ALL FLOORING INSTALLATIONS FAILURES ARE DUE TO SOME ASPECT

OF SUBFLOOR PREPARATION!

THREE MAIN CATEGORIES THREE MAIN CATEGORIES OF FAILUREOF FAILURE

EXCESSIVE MOISTURE VAPOR EMISSIONS

IMPROPER SUBSTRATE PREPARATION

IMPROPER USE OF “PATCH”

MoistureMoisture

Every manufacturer of floor covering has specific statements regarding the moisture content of the substrate to receive their flooring and the proper method of moisture testing.

CONCRETE & MOISTURE

Excess moisture in concrete slabs causes a variety of flooring failures, disrupting building operations and necessitating expensive repairs.

Consequences can be particularly serious in schools, hospitals and commercial installations where the loss of use of certain facilities, and hazardous conditions can jeopardize people’s safety, not to mention loss of business.

CONCRETE & MOISTURE

Refuse to install

Wait for the concrete to dry

Fix the problem

Accept a sign off from the general contractor!?Accept a sign off from the general contractor!?

When Moisture Testing FailsWhen Moisture Testing Fails

Subfloor PreparationSubfloor Preparation

ASTM F 710ASTM F 710 – Standard Practice for Preparing Concrete Floors to Receive

Resilient flooring

ASTM F 710ASTM F 710

Available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken PA 19428; [610] 832-9500; www.astm.org

Preparation of concrete slabs to receive resilient flooring

ASTM F 710 (cont.)ASTM F 710 (cont.)

Dry, clean, smooth, and structurally sound.

Free of dust, solvent, paint, wax, oil, grease, residual adhesive, adhesive removers; curing, sealing hardening, or parting compounds; alkaline salts, excessive carbonation or laitance, mold, mildew, and other foreign materials that might prevent adhesive bond

Calcium chloride moisture tests [ASTM F 1869]; results should be 3 pounds or less or resilient flooring manufacturer’s recommendations

ASTM F 710 (cont.)ASTM F 710 (cont.)

Relative Humidity [ASTM F2170] 75% or less

Alkalinity testing; maximum pH of 10

Don’t use adhesive removers.

Flatness requirements: ±1/8” in 10 feet

Drying time for slab: minimum of 60 to 90 days

Moisture retarders recommended under all on-grade and below-grade concrete floors.

Substrate Preparation Substrate Preparation The Key to Success!The Key to Success!

ConcreteConcrete

Concrete Subfloor PreparationConcrete Subfloor Preparation

Smooth, clean, dry

Free of ALL surface treatments and contaminants

Efflorescence

“Effervescence”

Efflorescence

Other ContaminantsOther Contaminants

Dry Wall Mud Paint Overspray Oil & Grease Asphalt or Tar

Other Contaminants (cont.)Other Contaminants (cont.)

Flooring Adhesives On a concrete substrate only. Not water soluble. Scrape to a thin well bonded residue.

Asbestos Adhesive - Wet-Scrape Only! Follow the guidelines of the Resilient Floor Covering Institute and comply with state and local laws.

Resilient Floor Covering Institute 401 East Jefferson Street, Suite 102 Rockville, Maryland 20850 Telephone: 301-340-8580 www.rfci.com

Mechanical Cleaning of ConcreteMechanical Cleaning of Concrete

Shot Blasting

Scarifying

Scabbling

Bush-Hammering

Grinding

Sand or Water Blasting

Shot blasting a Shot blasting a concrete surfaceconcrete surface

ScarifyingScarifying

GrindingGrinding

ScabblingScabbling

The use of sanding The use of sanding equipment is not equipment is not

sufficient to remove sufficient to remove curing and sealing curing and sealing

compounds from the compounds from the surface of concrete!surface of concrete!

Do not use Do not use chemicals such as chemicals such as adhesive removers adhesive removers or acid to prepare or acid to prepare

the concrete!the concrete!

Adhesive Removers

The only part of our industry that recommends adhesive removers are the adhesive remover manufacturers!

The use of solvents and “removers” on concrete will result in failure!

Mechanically clean the concrete!!!

Acid Etching

Cannot be 100% certain that acid is neutralized.

Introducing a tremendous amount of water to the concrete.

Mechanically clean the concrete!!!

Other Concrete SubstratesOther Concrete Substrates

Lightweight Concrete must

be structural lightweight!

Min. 3,000 psi in compressive

Min. 100 lb.cu.ft. in density

Cracks

Concrete Crack RepairConcrete Crack Repair

Repair of Cracks

All dormant cracks larger than hairline (1/32”) must be filled

V-out or “chase”

Fill full width and depth

Does not ensure against telegraphing in case of further movement

Joints in ConcreteJoints in Concrete

Expansion / Isolation Joints

Control / Contraction Joints

Summary-failure to properly Summary-failure to properly prepare a concrete substrateprepare a concrete substrate Mechanical preparation not used on

standard concrete

Concrete inherently weak – should have a tensile strength of at least 200 psi

Assumed no curing compound was used or that it had dissipated

Sealer remaining on concrete substrate

Used adhesive removers or acid etching

Adhesive residue too thick

Went over expansion joint

Went over moving crack

Went over isolation joint

Summary - failure to properly Summary - failure to properly prepare a concrete substrateprepare a concrete substrate

Non-Porous Substrates Substrates

Ceramic Tile

– make sure

tile is solidly

bonded.

MetalMake sure foils

are solidly adhered with epoxy!

Non-Porous Substrates Substrates

Epoxy Coatings

If these can be removed, do so. Don’t assume they are solidly bonded.

Non-Porous Substrates Substrates

Terrazzo

Make certain that sealers, waxes and dressings are completely removed.

Non-Porous Substrates Substrates

Summary - failure to properly prepare a Summary - failure to properly prepare a non-porous substratenon-porous substrate

Loose ceramic tile not removed.

Metal foil not solidly bonded.

Epoxy system flaky or disbonding.

Wax or dressing not stripped from terrazzo.

WOODWOOD

Wood Subfloors

Wood Subfloors

Plywood/OSBSolid Strip or Plank

• Make sure all are structurally sound and solid and installed

according to code.

Suitable for uses not permanently exposed to the weather.

Panels classified as Exposure 1

are intended to resist the effects of

moisture on structural performance due

to construction delays, or other conditions

of similar severity.

Type 1 PlywoodType 1 Plywood

• Prepared to bare wood

• Surface may require primer and the use of a lath mesh.

• Additive may be required to further accommodate movement.

• Joints must be filled full width and depth.

All wood must be:

Summary- failure to properly Summary- failure to properly prepare a wood subfloorprepare a wood subfloor

Wood not structurally sound

Inadequate fastening of wooden subfloor

Didn’t use lath or additive as required

Preparation of Substrates using Self-

leveling & Patching Materials

Hang in there!Hang in there!

Categories of Materials Used

Gypsum-based

Portland cement-based

Self-leveling

Trowel grade

Use a Portland cement-based material

Can be used on all grade levels

Can handle periodic moisture

Have similar compressive strengths

to that of the structural concrete –

3000 to 4000 psi

When to use a Trowel grade or Self-leveling Material

Do not base it on square footage.

Do not base it on substrate.

Do not base it on the thought that

trowel grade materials dry faster than

self-leveling materials.

When to use a Trowel grade or Self-leveling Material

Look at the thickness needed to achieve the required flatness or level of the concrete.1/8” or less use a patching material1/8” or greater float the substrate with a

self-leveling material.Look at the whether a slope is

required .

Selecting a Self-leveling Material

Versatility Installs over any common substrate –

concrete, non-porous, wood, metal & adhesive residues.

Installs to any thickness.Install flooring in 16 hours – even at any

thickness.Some Self-leveling materials can have

flooring installed in 2 hours.

Selecting a Self-leveling Material

Not all Self-leveling materials are the same.

Compare Apples to Apples.

Some materials may be limited to certain substrates.

Some materials may be limited in thickness.Some materials may take longer to dry – 2 to 3

days.

Selecting a Self-leveling Material

Select a material that fits the job.

Select a material that has a track record.

Select a material that is Portland Cement-based.

Select a material that is recommended by the flooring manufacturers.

Selecting a Patching Material

Decide whether a skim coating or ramping and sloping material is needed

Selecting a Patching Material

Ramping/Sloping Material

Fluid consistency that is easily screeded but can maintain slope.

Installs up to 3”Install flooring quickly – even at 3” in

thickness.

Selecting a Patching Material

Skim coating material

UnsandedInstalls over any common substrate –

concrete, non-porous, wood, metal & adhesive residues.

Dries quicklyHas excellent coverage.

Selecting a Patching Material

Not all Patching materials are the same.Once again, compare Apples to Apples.

Some materials may be limited to certain substrates.

Some materials may require an additive.Some materials may be limited in thickness.Some materials may take longer to dry – 1 to 3

days.Coverage per pound may vary from on product to

another.

Selecting a Patching Material

Select a material that fits the job.

Select a material that has a track record.

Select a material that is Portland Cement-based.

Select a material that is recommended by the flooring manufacturers.

What can go Wrong?What can go Wrong?

What can go Wrong?What can go Wrong?

Improper Product Selection

Improper Mixing

Improper Installation

Surface defects

Compatibility is critical!

Improper product selectionImproper product selection

Substrate not appropriate for the Self-

leveling or patching material.

Gypsum product used on or below grade.

Used self-leveling material instead of

trowel-grade material or the reverse.

Applied too thick.

Improper Mixing of the Self-Improper Mixing of the Self-leveling or patching materialleveling or patching material

“Over-watering” – the number one cause of failures when it comes to patching materials!

Didn’t use additive as required.

Improper Installation of the Self-Installation of the Self-leveling or patching materialleveling or patching material

Inadequate drying time allotted.

Primer applied too thick.

Wrong primer for type of substrate.

Surface defects not detected Surface defects not detected prior to installation of flooringprior to installation of flooring

Surface defects not detected Surface defects not detected prior to installation of flooringprior to installation of flooring

Flatness tolerance not achieved

Don’t have Don’t have time to do time to do

it right!it right!

Discipline!

Website/Phone/Etc.

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Free Training Seminars – go to www.ardex.com