Concrete self-leveling floor: pouring technology and alternative options

Welcome to "All about Concrete," where we explore the realm of applications for concrete. This article delves into the intriguing world of self-leveling floors, emphasizing the pouring technology and substitutes that are currently on the market.

Self-leveling floors’ exceptional capacity to produce seamless, smooth surfaces over sizable areas has completely transformed the flooring industry. Self-leveling concrete floors are made to flow and settle evenly on their own, as opposed to traditional concrete floors, which need substantial leveling and finishing. This technology is perfect for both residential and commercial spaces because it guarantees a smooth, level surface.

Pouring self-leveling floors requires a precise blend of high-flow concrete and polymers. Because of this mixture, the material spreads easily over the floor, filling in voids and leveling out uneven areas as it settles. Compared to traditional flooring options, the outcome is a smooth, consistent surface that requires less post-installation work.

If you’re looking for self-leveling floor alternatives, there are a few that can be tailored to your needs and preferences. Epoxy flooring is a well-liked option because of its strength and resistance to chemicals. Concrete floors that are already in place can have epoxy coatings applied to them to create a glossy, easily cleanable surface that can withstand heavy traffic.

Polished concrete is another option that is gaining popularity; it provides a more natural look while still having the advantages of durability and low maintenance. With polished concrete, the aggregate underneath is visible and the strength of the floor is increased by grinding the surface to a smooth finish.

Depending on the needs and goals of the project, each flooring option has advantages. Self-leveling floors are excellent at offering a rapid and effective way to achieve a perfect surface, but polished concrete and epoxy are flexible options with unique practical and aesthetic advantages.

We want to give you the knowledge you need to make wise choices for your next flooring project as we investigate pouring technology and alternative self-leveling floor options. Watch this space to find out more about how these creative solutions can change your area.

Floor leveling

First and foremost, you should be aware that installing concrete self-leveling floors will require a significant amount of time. One major benefit is that all work can be completed independently and no specialized construction knowledge is needed for the process.

Preparation

The process starts with examining and cleaning the old floor, just like with any screed. Everything, including the prior fill, will need to be removed in addition to the topcoat. Should the previous concrete covering be of low quality, it ought to be taken apart to expose the slabs.

This extensive disassembly is necessary not only to ensure a new self-leveling floor is installed to a high standard but also because self-leveling floors installed over older concrete will reduce the height of the room’s ceilings because self-leveling floors have a minimum thickness of 7 cm.

Take note! Examine the fill quality even if you bought a new apartment that needs to be completely renovated. If the builders did not maintain the mortar’s proportions, the screed may be soft and loose, in which case it is best to demolish the fill.

Pouring concrete screed

A self-leveling concrete floor is installed after the base has been prepped and cleared of debris.

The following is the order of work:

1. Priming the base. Deep penetration solutions should be used. Before priming, all existing cracks or depressions must be repaired. After the solution has been absorbed into the surface, usually after 2-3 hours, further work can be carried out.
2. Waterproofing. Depending on what your base will be, the film can be laid in different ways. The main requirement for roll material is overlapping with fixing the seams with construction tape.
3. Thermal insulation. Even if a horizontal heating system will be installed in this area in the future, it is necessary to lay the insulation material. This will eliminate significant energy losses, which is a very significant factor at current energy prices. Before you start laying, place the slabs without fixing them to determine the best cut. Laying the material starts from the far corner, fix the insulation, glue the joints and the perimeter at the walls.
4. Installing beacons. Focusing on the zero mark, fix the aluminum guides on the cement mortar. When installing, use a building level to avoid deviations from the horizon. Beacons should be located at a distance no greater than the size of the rule. The first line is fixed 0.3-0.5 m from the wall. After making sure that the guides are level, leave the mortar under them to harden.

1. Pouring concrete. The mortar is mixed in small portions so that it does not have time to set while you are working with the previous volume. The mortar is applied from the far corner and pulled out with a rule along the beacons. Do not rely on beacons, otherwise there is a risk of shifting the level.
2. Roller work. The poured screed must be rolled with a needle roller.
3. The screed is covered with polyethylene film and left to gain strength.

• The process of pouring concrete screed will take at least 4 weeks.
• If you try to save time by placing beacons on gypsum mortar, you will only add work to yourself.
• The guides will set faster, but after pouring, the gypsum will have to be removed from the screed, which will significantly add trouble and take a lot of time.

Concrete mortar can be used to create additional fills in addition to the primary rough screed.

Concrete volume calculator

Various pouring methods

Generally speaking, the pouring technique is determined by the base on which the mortar is applied and the intended use of the base for this fill.

It is conventionally accepted to distinguish three methods of pouring the solution:

1. Self-leveling floor on concrete. A situation when the fill is the finishing coating. The thickness of such a layer is no more than 1.5 cm. For better adhesion, the concrete base is sanded and primed before pouring. This method makes it possible to do without further finishing work, but requires perfect evenness. After drying, it is usually varnished or painted.
2. Two-layer pie: the solution is poured onto a base with fundamentally different physical properties – for example, wood. In order to prevent the properties of both materials from harming each other, a separating layer (polyethylene) is laid between them. The thickness of such a fill is no more than 2 cm.
3. Floating screed. In this case, the base can be similar to the fill – but a leveling layer is laid under the finishing material of a different property, for example: laminate or parquet. In this situation, a separating material (film) is also laid with an overlap on the walls and glued along the entire perimeter with a damper tape. The layer thickness is no more than 2.5 cm. After laying the decorative material, the remains of the film and tape are cut off, and the gap is closed with a plinth.

The pouring technology is the same regardless of the technique utilized to install self-leveling concrete floors:

• Work is carried out from the opposite corner towards the exit.
• You cannot rely on beacons.
• The rule is driven in a zigzag pattern.
• Do not leave a large volume of unleveled mortar on the floor.
• When mixing, it is necessary to strictly observe the proportions.
• After finishing the pouring, it should be covered with polyethylene, and access to the room should be closed.

Calculation of concrete composition

Materials for pouring

It is not just concrete mortar that can be used to level the floor. You can make your own cement mortar or buy dry building mixes. Furthermore, a large variety of self-leveling mixtures exist. Therefore, selecting the appropriate material is just as important as understanding pouring technology.

Let’s examine how different compositions perform in comparison:

All ready-made dry mix packages come with comprehensive application instructions. Cement-sand mixture (CSM) can be independently made by combining 1:3 sifted fine river sand with M500 cement.

Depending on the type of screed being poured, different concrete solutions have different proportions. The self-leveling floors in this series are the most intriguing. A little further on them.

This article for "All about Concrete" delves into the pouring process and compares it with other options as we examine the cutting edge technology of self-leveling floors. Smooth and even surfaces can be easily achieved with self-leveling floors, making them perfect for a range of settings, including both residential and commercial areas. We’ll go over the precise steps involved in pouring these floors, emphasizing important factors like the materials needed and the amount of preparation required. We’ll also discuss substitute flooring choices that offer comparable advantages but might have different setup and upkeep needs. Making educated decisions regarding your flooring needs will be made easier if you are aware of these options, whether you’re building a new industrial space or remodeling a home.

Self-leveling floors

It is important to note right away that mixtures for self-leveling floors are separated into levelers and finishing. In addition, the usage instructions dictate that a finishing layer of the same brand must be poured after using a branded leveler as a base. On any base, however, the finishing layer itself can be applied.

What is the primary distinction between the mixtures?

• Levelers, in fact, are a replacement for a rough screed. Mixtures are applied along beacons, using a technology similar to applying concrete mortar. Leveling with a rule is required.
• The finishing mixture, as the name suggests, can be a decorative finish. The application layer is no more than 30 mm. They have very good fluidity and do not require additional leveling.

Every construction brand that releases a leveler also inevitably provides a finishing fill. The image displays multiple options.

Modern building material manufacturers offer a variety of composition mixtures and pouring techniques to help level the floor. Self-leveling floors are a workable solution, but you should consider the type of composition and pouring conditions beforehand.

Types of mixtures

The following characteristics set all current varieties of mixtures for self-leveling floor installations apart:

Layer height	Highly filled and thin-layer
Participating mixer	Water and solvent
Electrical conductivity	Antistatic and electrically conductive
Texture	Smooth and rough

Knowing what binder the mixture is based on is crucial in addition to these indicators.

The following mixes are available for purchase on the construction industry:

• Polyurethane. The basis is transparent polyaspartates. The finished floors are highly elastic, resistant to color fading. Give owners the opportunity to create 3D images on the surface. At the same time, they have very low resistance to mechanical impacts.
• Epoxy. Made from epoxy resin and quartz sand using a hardener. Have very high resistance to chemical and physical impacts. The highest price tag of all possible options and a long curing period.
• Cement-acrylic. They tolerate physical stress well, have an anti-slip effect, are suitable for outdoor use. A significant disadvantage is the high labor costs during installation.
• Methyl methacrylate. Dries very quickly, suitable for rooms with a high vertical static load (production shops). Toxic when pouring, it is necessary to observe safety precautions.

More about pouring conditions

The only prerequisite for a concrete base for self-leveling floors, regardless of mixture type, is that the surface must be flawless and of excellent quality. The floor takes a different amount of time to dry depending on the type of mixture. You can usually use the surface three to four weeks after that.

And you ought to be aware of the following conditions during this time:

• It is necessary to maintain a constant temperature inside the room. The ideal conditions are a temperature within +15 – +25 degrees.
• When applying, the humidity of the concrete base should not be higher than 4%.
• To maintain these parameters, drafts should be avoided in the room.

Instructions for pouring the floor

Make sure you follow the directions on the packaging if you choose to pour the floor yourself.

Although every mixture is unique, the general process for completing the work is as follows:

1. Mix the solution, strictly observing the proportions specified by the manufacturer. The optimal composition is similar in consistency to thick sour cream.
2. Pour the composition onto the base of the floor, and spread it with a wide spatula. Minimum pouring thickness is 5 mm. You can make the layer thicker – this will increase the strength, but will entail a significant increase in the financial part of the costs.
3. Walk over the surface with a needle roller to expel air from the composition.

Crucial! When applying a mixture to a water solution, adding more water will improve spreadability but cause cracking when it dries.

The work is complete if the floor was leveled beneath ornamental sheet or roll material. However, if a final pouring is intended, then the entire work cycle needs to be repeated, this time using a finishing solution, after it has completely dried.

The finishing layer should first be shielded from water and sunlight after it has completely dried.

Take note! Any type of decorative finish, such as laminate, parquet, tiles, or linoleum, can be used beneath self-leveling floors. Arranging a self-leveling floor beneath concrete is the only thing that makes no sense.

This article’s video will provide an overview of the self-leveling floor technology.

Calculation of concrete composition

When selecting flooring for your area, it’s important to take a number of factors into account, including aesthetic appeal, ease of installation, and durability. Because of their smooth, seamless finish and adaptability to both residential and commercial settings, concrete self-leveling floors have grown in popularity. Pouring technology guarantees a level and imperfect-free floor, which makes it the perfect option for spaces that need a perfect surface.

The adaptability of concrete self-leveling floors to various environments is one of their main benefits. These floors can be tailored to meet specific design specifications, whether you’re remodeling a showroom, office space, or kitchen. To achieve a uniform thickness, they are poured onto subfloors that have been prepared and evenly spread using specialized tools. This procedure not only makes the floor more aesthetically pleasing but also more functional overall.

Epoxy and resin-based coatings present good alternatives for individuals looking for self-leveling floor alternatives other than concrete. The benefits of these materials are comparable in terms of adaptability and longevity. For example, epoxy floors are renowned for their strength and resistance to chemicals, which makes them appropriate for use in industrial settings. Conversely, floors made of resin provide a more ornamental finish in a variety of hues and patterns.

The decision between alternative options and concrete self-leveling floors ultimately comes down to your personal preferences and needs. Concrete self-leveling floors are a great option if a seamless, easily maintained surface that can handle heavy use is important to you. Conversely, investigating epoxy or resin-based coatings may be more appropriate if you’re looking for a flooring solution that provides more design flexibility or particular performance attributes like chemical resistance.

Regardless of the option you select, longevity and satisfaction with your flooring investment are guaranteed when you invest in high-quality materials and professional installation. To choose the best flooring option for your room, consider your priorities and speak with professionals. Every type of flooring has advantages of its own.