Concrete screed made of polystyrene is an excellent way to provide a smooth, long-lasting surface and insulate your floor. This lightweight material is a great option for both new construction and renovations because it combines the strength of concrete with the insulating qualities of polystyrene.
The simplicity of use of polystyrene concrete is one of its key benefits. A polystyrene concrete screed can be made by anyone, even if they are not experienced builders. If you have the proper supplies and a well-defined, step-by-step plan, you can finish this project by yourself.
You will be guided through every step of the procedure by this guide, which includes setting up your workspace and mixing and applying the polystyrene concrete. Polystyrene concrete screed is a workable and efficient solution, whether your goal is to increase your home’s energy efficiency or just have a smoother, more even floor.
| Step | Description |
| 1. Prepare the Surface | Clean the floor thoroughly and remove any debris or dust. |
| 2. Install Insulation | Lay down insulation sheets to improve thermal efficiency. |
| 3. Set Up a Perimeter | Place edge strips around the room to allow for expansion. |
| 4. Mix the Concrete | Combine cement, water, and polystyrene beads in a mixer. |
| 5. Pour the Mixture | Pour the polystyrene concrete mixture onto the floor evenly. |
| 6. Level the Surface | Use a screed or a straight edge to level the concrete. |
| 7. Allow to Cure | Let the screed cure for at least 24 hours before walking on it. |
| 8. Finish the Surface | After curing, finish the surface as desired, such as sanding. |
- Polystyrene concrete composition
- Advantages
- Disadvantages
- Concrete production
- Cost of polystyrene concrete
- Types of screeds
- Screed manufacturing process
- Break of solution
- Alternative to foaming agent
- Pouring and leveling
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Polystyrene concrete composition
One particular material that has a cellular structure and is relatively light is polystyrene concrete.
- polystyrene granules 2-5 mm;
- Portland cement M400;
- foaming additives;
- quartz sand;
- plasticizers.
The composition’s component proportions are determined by the future usage circumstances of the coating. Cement is added in greater proportion to the other components in order to strengthen the solution. The percentage of polystyrene granules in the composition should be between 60 and 80 percent.
A specific plasticizer, which will boost the solution’s plasticity and lower the possibility of floating polystyrene granules, should account for at least 10% of the mixture.
To ensure that all of the ingredients in the solution are distributed equally, it must be thoroughly mixed.
Making your own polystyrene concrete screed is a quick and effective method to have a lightweight, insulated floor. From gathering supplies to adding the finishing touches, this step-by-step guide will walk you through the process to ensure you can finish the project confidently and easily. With easy-to-follow directions and helpful hints, even novices can create a long-lasting, superior screed.
Advantages
Polystyrene concrete makes a coating that has a low heat conductivity, so you don’t need extra insulation when pouring it on the floor. Additionally, because this composition is relatively light, using it for screed enables you to lessen the load on the base.
- durability;
- filling all cracks;
- good sound insulation;
- environmental friendliness;
- easy installation.
A coating like this offers excellent rodent protection. Rats and mice frequently find refuge in sheet polystyrene insulation cakes; however, this material is dependable rodent proof when it is supplied as granules covered in concrete mortar.
Granules’ material has a high level of moisture resistance. It is advised to be utilized for floor arrangement in private residences with high air humidity levels, as well as in restrooms, kitchens, and hallways. This material also has a high degree of resistance to frost. It has a minimum of 100 cycles of freezing and defrosting.
Since the hardened material has a low vapor permeability, installing it doesn’t require the use of a vapor barrier film. This composition’s non-flammability is another benefit. Even an open flame cannot penetrate the polystyrene granules found in concrete mortar.
Furthermore, there is no need to lay additional waterproofing when installing such a screed. Since the screed spreads easily, all of the voids are filled in. When utility lines need to be repaired, it is simpler to mechanically affect this type of coating than it is a concrete screed. The inexpensive cost of the ingredients needed to make the solution is another benefit of this coating.
Disadvantages
Although polystyrene concrete screed offers numerous advantages, it also has certain drawbacks. It is not advised to use this flooring in rooms with a lot of vibration.
In the presence of vibration, the porous structure is prone to rapid cracking. For this reason, flooring in industrial buildings and production workshops should not be made of this material.
Concrete floor screeds made of polystyrene are also weak. A split can result from any mechanical impact. If there is no flooring, the surface ages rapidly. Using specific compounds to strengthen it is essential.
Due to the high degree of shrinkage in this material, a vibrating machine must be used during the pouring process in large rooms. The uneven surface of the screed created by using polystyrene concrete makes it more difficult to install various kinds of floor coverings. It might be required to pour a strengthening mixture to level and fortify the surface.
Concrete production
Because the filler in the polystyrene concrete solution is lightweight, you can mix it yourself. However, you can use a construction whisk and a concrete mixer to speed up the process.
It is advised to buy or prepare a specific dry mixture that contains polymer additives on your own.
- polystyrene granules – 1 m³;
- cement — 290 kg;
- powdered SDO — 0.7 l of concentrate;
- plasticizers;
- water — 120 l.
The polystyrene foam granules are uniformly distributed in a thick solution that is created by gradually combining these ingredients.
Cost of polystyrene concrete
A ready-made dry mix that includes polystyrene costs between 3200 and 6800 rubles. The cost of each component affects the final cost of a self-prepared mixture.
Types of screeds
Thermal insulation and structural polystyrene concrete screeds are the two varieties available. A less dense solution with a higher thermal conductivity coefficient is made in the first scenario. With this mixture, you can make a screed with good heat retention. Its resistance to mechanical damage is low, and it can only bear a lesser load.
The preparation of a dense solution with a weight of 600 kg per m³ is the second option. Although this type of screed is more robust and abrasion-resistant, its heat retention is inferior.
Screed manufacturing process
You can use your own polystyrene concrete to fill the screed. The base needs to be prepared first. Along with taking out all of the furniture and other items, you should also take off the previous coating.
If these protrusions are too big, the old mortar build-ups have to be removed. Dust and debris must be removed from the surface. Existing floor cracks are sealed with cement mortar. Applying primer multiple times will help to improve the screed’s clutch with the base.
The perimeter of the walls needs to be sealed with damper tape in order to prevent the screed from cracking as a result of concrete expanding during temperature changes. Adhere the tape so that it sticks out 3–5 cm above the screed.
The beacons should then be positioned. You can make use of wooden bars, cords, or metal guides. It is necessary to verify that the guides are installed correctly using the laser level. After that, you can move on to the solution batch and its filling.
Break of solution
Use the manufacturer’s instructions for preparation of the solution if the finished dry mixture is going to be used to fill the screed.
Since polystyrene has a large volume, a mixture should be made in small portions when working independently. On the other hand, you can prepare it immediately if you have a large container and the capacity to mix the necessary amount of solution at the same time.
The solution will be prepared by first adding roughly 10% water to a container containing polystyrene granules. Using a construction whisk, the mass is thoroughly mixed, ensuring that the granules are wet.
Cement is then applied after that. It is required to fully combine the mass and add approximately 85% of water to the mixture. SDO needs to be dissolved in the remaining water before being added to the container. After that, the mixture needs to be brought to a sour cream consistency.
Alternative to foaming agent
Not all concrete porosity-boosting additives are readily available for purchase. It is simple to find a substitute for them, though. The final step in making the solution is to add a detergent to the mass that has been diluted with a small amount of water. It will foam during mixing, which will fill the composition with a lot of tiny air bubbles.
Pouring and leveling
Make sure the base is completely moist before putting in the screed. You can use water or cement milk for this. This is required to increase the solution’s adherence to the surface. After that, you can begin screed installation. Its recommended thickness ranges from 3 to 8 cm. The mixture needs to be carefully arranged so that it rises 1-2 cm above the beacons. A rule based on the beacons’ levels should be used to level the surface. You also need to make sure that the screed is free of cavities.
To prevent drafts from affecting the screed, all doors and windows in the room where the base arrangement work is done must be closed. Once the beacons are initially set, you can remove them if needed.
It is advised to cover the base’s surface with polyethylene film for up to seven days in order to improve the solution’s drying and hasten the development of its strength.
If the area being worked on is larger than thirty meters square, damper joints should be left exposed. This will lessen the possibility of future surface cracking. You can pour a self-leveling mixture about 14 days following the work. 3 to 5 cm should be its thickness. Once it solidifies, you can begin applying decorative finishing.
Self-constructing a polystyrene concrete screed can be a rewarding and manageable project. You can achieve a lightweight, insulated screed that improves the performance and comfort of your flooring by carefully following the step-by-step plan.
Having the proper supplies, precise measurements, and careful preparation are essential for the entire process. A strong and efficient screed can be achieved by making sure the mixture is consistent and applying it correctly.
Concrete screeds made of polystyrene have several benefits, such as decreased structural load and enhanced thermal insulation. You can take advantage of these advantages in your own home improvement projects if you take the proper approach.
