Fast-Track Waterproofing for Concrete Floors
In commercial environments and other sectors such as education and healthcare, fast-track construction is a necessity and installation of the waterproofing membrane and flooring system is often one of the highest priorities in order that other trades can progress. Floor spaces cannot be taken out of service for long periods of time, so it important that downtime is kept to an absolute minimum, whilst waterproof, durable floor protection is reinstated.Download file: Solutions for Floors Trafficked Areas
Outstanding Track Record
Flexcrete’s fast-track cementitious flooring systems have an outstanding track record of successful use in industrial factories, retail facilities, sports halls, car parks, shopping centres and hotels to name a few. McDonald’s, Scotland’s Gleneagles Hotel and even the famous Golden Gate Bridge in San Francisco have all benefited from our advanced polymer cement technology. Flexcrete offers a complete one-stop solution for waterproofing concrete floors, and provides a wide range of effective systems.
Our fast setting concrete repair mortars allow for the rapid reinstatement of vehicular and foot traffic, whilst our high performance cementitious coatings can be used for temporary concrete waterproofing. In addition, our hard-wearing epoxy and cementitious flooring systems provide years of effective waterproof, abrasion and chemical resistant protection.
Flexcrete’s floor coating systems are designed to speed up the construction process and bring schedules back on track; in many instances they are used as flooring finishes in their own right, but they can also be overlaid with other flooring materials such as vinyl, resin finishes or carpet.
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Flooring Systems Problems and Solutions
- Water infiltration
- Osmotic Blistering
- Freeze-Thaw and Trafficking Exposure
- Reinstating Joint Nosings
- Rapid Concrete Floor Repairs
- Levelling Concrete Floors
- Crazing of Decorative Coating
Active water infiltration must first be arrested using Fastfill WP, a rapid setting, Portland cement based mortar which sets in 2 minutes. This non-caustic mortar is more reliable and safer to use than traditional cement admixtures.
The surface is then saturated before priming with Cemprotec EF Primer, to seal the concrete prior to the application of a 2mm coat of Cemprotec E-Floor. This high performance cement and epoxy modified polymer coating is capable of withstanding 10 bar hydrostatic pressure yet is tough and durable enough to withstand heavy trafficking.
Cemprotec E-Floor is applied to prepared and saturated concrete floors that have been primed with Cemprotec EF Primer. It is poured out and spread to a minimum 2mm thickness prior to de-airentraining with a spiked roller.
To aid curing and enhance the adhesion of any coatings that may be subsequently applied, a fine quartz sand can be broadcast into the surface of the freshly laid material. Only 48 hours curing is required before impervious floor coatings and finishes can be laid, which will be resistant to subsequent osmotic blistering. Please consult our technical department regarding compatibility tests.
All potholes and damaged areas are first reinstated with Fastfill, a shrinkage compensated, fibre reinforced, Portland cement based mortar, which sets in 10 minutes.
Following saturation of the substrate and priming with Cemprotec EF Primer, the mixed Cemprotec E-Floor HB is poured out and spread to a minimum depth of 3-6mm using a skid leveller, prior to spike rollering to remove entrapped air. Whilst the surface is still wet a dried, quartz sand is broadcast into the surface to provide a slip resistant finish and to aid curing. Excess sand can be removed after a minimum cure time of 4 hours. To enhance longevity the surface can then be sealed with Cemprotec Sandseal 75.
After a minimum of 4 hours curing, the excess sand is removed and the surface sealed with Cemprotec Sandseal 75, a clear, non-yellowing, high performance moisture triggered coating is applied by squeegee or roller. This hard wearing coating exhibits excellent chemical resistance and increase the durability of the slip resistant finish.
Following breaking out of unsound concrete and thorough saturation of the substrate, joint nosings on floor slabs or treads on stairs can be reinstated with Fastfill. This shrinkage compensated, Portland cement based mortar, which benefits from polymer and fibre modification, sets within 10 minutes to give a durable reliable repair even in the most heavily trafficked areas.
When carrying out deeper repairs, the product can be bulked out with either a coarse aggregate or a sharp concreting sand to provide a cost effective solution.
All areas should be thoroughly prepared to remove contamination and unsound concrete and the edges of the repair stepped to a minimum depth of 10mm to prevent feather edging. Ensure that the substrate is saturated without any standing water.
Where speed of reinstatement is important, all voids and removed concrete should be reinstated with Fastfill, a shrinkage compensated, polymer modified, Portland cement based repair mortar, which sets in 10 minutes.
In areas where speed is not critical, Monomix HD, a single component, high strength, polymer modified fibre reinforced mortar, provides a durable solution.
If concrete floors have extremely uneven surfaces, it is important to level them out prior to the installation of a flooring system. Cemprotec Levelling Coat is ideal for use as a flowing screed prior to the application of Cemprotec E-Floor or Cemprotec E-Floor HB in applications where the concrete substrate is particularly uneven.
Cemprotec Levelling Coat is always used as a base layer for another floor protection product over the top. It is ultimately designed for use with Cemprotec E-Floor (where a 2-3mm thick flooring system is required) or Cemprotec E-Floor HB (where a 3-6mm finished application is desired) but it can also be used in conjunction with alternative flooring systems such as polyurethanes, epoxy-based systems, polyureas and methyl methacrylate.
Monolevel 250F fine grade cementitious fairing coat should then be used to level out the surface of the balcony area and provide an even surface before re-coating can be carried out.
Monolevel 250F can be applied up to 4mm in a single layer and can be feather edged. Bond-Prime should be used to seal the substrate before the application of one or a combination of Flex-crete’s Monodex protective coatings.
This repair and protection system will transform the appearance of balconies, providing excellent waterproof and anti-carbonation protection for up to 15 years.
Flooring Systems Products
Find out more about Flexcrete’s range of concrete floor repair and protection products below:
|Cemprotec E-Floor||Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (2mm)|
|Cemprotec E-Floor HB||Epoxy and cement modified polymer coating for protecting / waterproofing concrete floors. (3-6mm)|
|Cemprotec EF Grit||Quartz aggregate for abrasion and skid resistance within E-Floor systems.|
|Cemprotec EF Primer||Single component sealer and primer for floors, prior to the application of the Cemprotec range.|
|Cemprotec Levelling Coat||Self-levelling cementitious mortar for concrete floors prior to the application of Cemprotec E-Floor or Cemprotec E-Floor HB.|
|Cemprotec Sandseal 75||Clear, hard wearing, single component, polyurethane coating for protecting / sealing Cemprotec E-Floor.|
|Cemprotec Sandseal WB||A clear, water-based sealer for protecting concrete floors.|
|Fastfill||Rapid setting concrete repair mortar. Can be bulked out in deep sections.|
Flooring Systems Projects
Take a look below at some of Flexcrete’s latest concrete floor repair projects, or browse the project profile pages to find more.