the choice of professionals ™ seth pevarnik manager of technical service
TRANSCRIPT
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