Application Manual Version 1 3z5p35

Application Manual for MASTERTOP Cementitious Floors 1st Issue – Version January 2010

BASF Construction Chemicals Product Management Europe c/o PCI Augsburg GmbH Piccardstr. 11 86159 Augsburg

1. Content 1. 2. 3.

Content................................................................................................................................................. 2 Introduction .......................................................................................................................................... 3 Dry Shake surface hardeners .............................................................................................................. 4 3.1. Concrete............................................................................................................................................ 4 3.2. Slab Design ..................................................................................................................................... 10 3.3. Summary of Products...................................................................................................................... 11 3.4. Application Procedures – How to install a proper dry shake floor .................................................. 12 3.4.1. Manual Application (e.g. with shovel) .......................................................................................13 3.4.2. Spreader application .................................................................................................................15 3.4.3. Laser screed application ...........................................................................................................17 3.5. Types of floors:................................................................................................................................ 19 3.5.1. Standard floors:.........................................................................................................................19 3.5.2. Coloured floors..........................................................................................................................19 3.5.3. Aesthetic floors: ........................................................................................................................20 3.5.4. Light reflective floors: ................................................................................................................20 3.5.5. Antistatic floors – Installation of MASTERTOP 201..................................................................21 4. Pumpable products................................................................................................................................. 23 4.1. Concrete mix design........................................................................................................................ 23 4.2. Slab construction............................................................................................................................. 23 4.3. Summary of products ...................................................................................................................... 23 4.4. Application procedures.................................................................................................................... 24 4.4.1. Installation onto freshly poured concrete ..................................................................................24 4.4.2. Installation on existing concrete................................................................................................26 5. Screedable Topping – MASTERTOP 210 / 230..................................................................................... 27 5.1. Application procedures.................................................................................................................... 27 5.1.1. Installation onto freshly poured concrete ..................................................................................27 5.1.2. Installation on existing concrete................................................................................................28 6. Trouble shooting ..................................................................................................................................... 30 6.1. Bleeding of concrete........................................................................................................................ 30 6.2. Wind ............................................................................................................................................. 30 6.3. Dry shake is applied too early ......................................................................................................... 31 6.4. Dry shake is applied too late ........................................................................................................... 31 6.5. The floor is uneven in colour or even grey ...................................................................................... 31 6.6. Potential defects in concrete floors ................................................................................................. 31 7. Repairs ................................................................................................................................................... 32 7.1. Local Repair of ts and Corners................................................................................................. 32 7.2. Local repairs in existing concrete substrate or damaged final floors .............................................. 33 7.2.1. Universal floor repair options ....................................................................................................33 7.2.2. Repairs ("like-with-like"), limited to repairs < 20 mm thickness ................................................34 8. Curings ................................................................................................................................................... 34 9. ts ...................................................................................................................................................... 36 9.1. Types of ts ................................................................................................................................. 36 9.2. MASTERTOP armoured ts ........................................................................................................ 40 9.3. MASTERFLEX 474 ......................................................................................................................... 41 10. Tools ..................................................................................................................................................... 43 11. Recommendation on Job Site Organisation......................................................................................... 43 11.1. Safety and precautions ................................................................................................................. 43 11.2. Field Service.................................................................................................................................. 44 11.3. Job Site Organization .................................................................................................................... 44 12. Maintenance ......................................................................................................................................... 44 13. General limitations of cementitious floors............................................................................................. 48 14. ing Documents ......................................................................................................................... 48

Application Manual Cementitious Flooring Products

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Version 1 (January 2010)

2. Introduction General This manual is a guide for applicators laying MASTERTOP cementitious flooring systems. Compliance with the procedures described should ensure that end-s are provided with a floor having the benefits that are associated with MASTERTOP floors. It is assumed that applicators of MASTERTOP flooring are experienced installers of cementitious flooring. On-site operations, including the assessment of substrates, especially in refurbishment situations, the use of proper and safe working practices, and estimating, are in the applicators' area of expertise and remain their responsibility. The manual contains recommendations based upon our knowledge of MASTERTOP flooring, extensive laboratory testing and more than 90 years of successful specification worldwide.

Aim of the manual This application manual was designed to meet certain specific objectives. It should create in applicators and owners of MASTERTOP Technology

cementitious floors the awareness that the total floor system is a combination of the three elements of a floor: the subgrade, the concrete and the surface and that the interaction

between

High Quality Concrete Floors

technology,

workmanship and quality products are important factors. As a company involved in

Workmanship

Quality Products

the marketing of high performance floor systems it is essential that the customers and s of BASF products understand the importance of correct planning and installation. It is critical that each element of the whole floor system is properly designed and constructed; only then the customer will realize the true potential of his investment. The document should provide guidance on good practice in the use of dry shake finishes on concrete floors and advice on avoiding problems.


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3. Dry Shake surface hardeners Dry shake materials are blends of a special cements, aggregates, ixtures and pigments that are factory blended or pre-mixed and supplied in bags or big bags. They are used to improve the surface of concrete floors in of abrasion resistance, cleanability and also for aesthetic purposes. As a consequence the durability and life time of a floor is increased significantly and maintenance costs are reduced. The final quality of a high performance cementitious floor not only depends on the surface product but also on the design and quality of the concrete below. Therefore we would like to give a complete overview of the whole installation process starting from the concrete to application of the MASTERTOP product and the installation of ts. Note: The responsibility for the stability of the subgrade /sub-base before concrete is placed lies in the responsibility of the designer/owner.

3.1. Concrete The consistency of the supplied concrete is of high importance for the installation of a dry shake floor. Concrete mix design and production should follow the guidance of EN 206-1:2000. Important factors that determine the composition of concrete are described as follows and are cited here as described in EN 206-1: •

Exposure classes related to environmental actions

The environmental actions are classified as exposure classes. The exposure classes to be selected depend on the provisions valid in the place of use of the concrete. This exposure classification does not exclude consideration of special conditions existing in the place of use of the concrete or the application of protective measures such as the use of stainless steel or other corrosion resistant metal and the use of protective coatings for the concrete or the reinforcement. The concrete may be subject to more than one of the actions described. The environmental conditions to which it is subjected may thus need to be expressed as a combination of exposure classes. Details and examples are given on the next page.


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Class Description of the environment designation No risk of corrosion or attack X0 For concrete without reinforcement or embedded metal: all exposures, except where there is freeze/thaw, abrasion or chemical attack For concrete with reinforcement or embedded metal: very dry Corrosion induced by carbonation XC1 Dry or permanently wet. XC2

Wet, rarely dry

XC3

Moderate humidity

XC4

Cyclic wet and dry

Corrosion induced by chlorides other than from sea water XD1 Moderate humidity XD2

Wet, rarely dry

XD3

Cyclic wet and dry

Corrosion induced by chlorides from sea water XS1 Exposed to airborne salt but not in direct with sea water XS2 Permanently submerged XS3 Tidal, splash and spray zones Freeze/thaw attack with or without de-icing agents XF1 Moderate water saturation, without de-icing agent XF2 Moderate water saturation, with de-icing agent XF3 XF4

Chemical Attack XA1 XA2 XA3

High water saturation, without de-icing agent High water saturation, with de-icing agent

Slightly aggressive chemical environment according to Table 2.2.2 in EN 206-1 Moderately aggressive chemical environment according to Table 2.2.2 in EN 206-1 Highly aggressive chemical environment according to Table 2.2.2 in EN 206-1


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Informative examples where exposure classes may occur Concrete inside buildings with low air humidity

Concrete inside buildings with low air humidity. Concrete permanently submerged in water Concrete surfaces subject to long-term water ; many foundations Concrete inside buildings with moderate or high air humidity; external concrete sheltered from rain Concrete surfaces subject to water , not within exposure Class X C 2 Concrete surfaces exposed to airborne chlorides Swimming pools; concrete exposed to industrial waters containing chlorides Parts of bridges exposed to spray containing chlorides; pavements; car park slabs Structures near to or on the coast Parts of marine structures Parts of marine structures Vertical concrete surfaces exposed to rain and freezing Vertical concrete surfaces of road structures exposed to freezing and airborne de-icing agents Horizontal concrete surfaces exposed to rain and freezing Road and bridge decks exposed to deicing agents; concrete surfaces exposed to direct spray containing de-icing agents and freezing Concrete in treatment plants; slurry containers Concrete components in with sea water; components in soil corrosive to concrete Industrial effluent plants with effluent corrosive to concrete; silage tanks; concrete structures for discharge of flue gases


Exposure classes according to EN 206-1 related to environmental actions – examples

Classification by Consistence The classes of consistence in the tables below are not directly related. For moist concrete, i.e. concrete with low water content, the consistence is not classified.

Compaction classes

Slump classes

Class

Class

Degree of compactability

Slump in mm

C0

≥1.46

S1

10 to 40

C1

1.45 to 1.26

S2

50 to 90

C2

1.25 to 1.11

S3

100 to 150

C3

1.10 to 1.04

S4

160 to 210

S5

≥ 220

Flow classes Class

Flow diameter in mm (spread)

F1

≤ 340

F2

350 to 410

F3

420 to 480

F4

490 to 550

F5

560 to 620

F6

≥630


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•

Compressive Strength Classes

The characteristic compressive strength of either 150 mm diameter by 300 mm cylinders or of 150 mm cubes may be used for classification. Compressive

Minimum characteristic cylinder strength

Minimum characteristic cube strength

fck.cyl [N/mm²]

fck.cube [N/mm²]

C 8 / 10

8

10

C 12 / 15

12

15

C 16 / 20

16

20

C 20 / 25

20

25

C 25 / 30

25

30

C 30 / 37

30

37

C 35 / 45

35

45

C 40 / 50

40

50

C 45 / 55

45

55

C 50 / 60

50

60

C 55 / 67

55

67

C 60 / 75

60

75

C 70 / 85

70

85

C 80 / 95

80

95

C 90 / 105

90

105

C 100 / 115

100

115

Strength Class

•

Extract from EN 206-1: Annex F: Recommended limiting values for composition and properties of concrete See next page


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Please consider the following topics concerning the composition of the concrete used: •

Cement type: CEM I – CEM III types can be used according to EN 206-1.

•

Cement quantity: minimum 260 – 360 kg/ m3

•

Fillers: addition of either fly- ash, silica fume and limestone is allowed

•

W/C ratio: according to EN 206-1, but for floors 0.50 to 0.55 is recommended except if lower W/C factors are requested due to exposure class.

•

Aggregates: well graded sand and coarse aggregates with a Dmax of 32 mm, for better performance use Dmax of 20 mm.

•

ixtures: POZZOLITH plasticizer or RHEOBUILD/GLENIUM superplasticizers without air entrainment and no chloride neither chloride containing ixtures!

•

Fibres: addition of steel fibres or other fibres depending on the load barrier of the concrete substrate afterwards.

•

Use a concrete mixture of the required strength design with a slump of 75 mm minimum and with no more than 3% entrained air.

•

For heavy-duty traffic areas, concrete designed for at least C 25/30 up to 30/37 N/mm² should be used. Thickness of the slab and the type and amount of reinforcement in it are important design considerations.

•

To minimize shrinkage cracking, we advise the use of a suitable POZZOLITH plasticizer or RHEOBUILD/ GLENIUM super plasticizer.

•

At high temperatures, at low humidity or when placing concrete without protection from wind or sun, the evaporation retardant MASTERTOP C711CF (MASTERKURE 111CF) should be applied on the concrete surface.

•

Do not use salt water or salt contaminated aggregate in concrete over which MASTERTOP 200, 200 P, 201, 210 or 230 will be applied.

•

MASTERTOP C 711CF (MASTERKURE 111CF) – An Evaporation Retardant

MASTERTOP C 711CF (MASTERKURE 111CF) is no curing but an evaporation retardant and finishing aid that helps to produce high quality concrete flatwork. It retards water evaporation, regulates the surface condition of the slab and permits better adherence to finishing schedules. Because MASTERTOP C 711CF (MASTERKURE 111CF) retards evaporation, it is especially effective in combating rapid drying conditions (high concrete and/or ambient temperatures, low humidity, high winds, direct sunlight, work in heated interiors during cold weather, etc.) It reduces surface moisture evaporation by about 80% in windy and by about 40% in sunny conditions. It has no effect on the cement hydration process. Concrete strength (early and ultimate), Application Manual Cementitious Flooring Products

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abrasion resistance and durability are not altered, except for the improvement in overall quality resulting from control of rapid evaporation. It eliminates or reduces crusting, stickiness and underlaying sponginess which often results in unevenness and poor surface texture. The surface closes better under the trowel. The product reduces and, in many instances, eliminates plastic shrinkage cracking and wind crusting of flatwork surfaces. Also supplements the recommended practises for hot weather concreting. Under some conditions, MASTERTOP C 711CF (MASTERKURE 111CF) will provide the necessary safeguard against the ill effects of evaporation. It is recommended to apply the product onto the levelled concrete under hot and windy conditions before the application of the MASTERTOP cementitious flooring products. MASTERTOP C 711CF (MASTERKURE 111CF) is NOT a curing agent. Concrete treated with this product must still be cured! MASTERTOP C 711CF (MASTERKURE 111CF) reduces evaporation only while concrete is in its plastic state. It is not a substitute for early curing of hardened concrete, nor does it alter the effectiveness of membrane type, curing compounds. Application: Apply MASTERTOP C 711CF (MASTERKURE 111CF) with an ordinary, garden type, tank sprayer or with the equipment used for application of a spray-on, membrane-type curing compound. MASTERTOP C 711CF (MASTERKURE 111CF) contains a fluorescent colour tint which disappears completely upon drying. When sprayed onto the surface immediately after screeding, MASTERTOP C 711CF (MASTERKURE 111CF) forms a monomolecular film. This film is easily distinguished from untreated surfaces by its green-yellow colour in the presence of surface moisture and ultraviolet rays (sunlight or artificial lighting). The residue remaining on the surface of hardened concrete does not impair bonding or alter the colour appearance. The protective shield usually lasts as long as the concrete remains plastic, despite succeeding floating and towelling operations.

3.2. Slab Design Before determining the structural details of a floor the design should first consider the overall design

wearing surface or topping

data starting from the surface downwards. The following data can considerably influence the specification decisions and design of the floor. •

Surface characteristics: impact abrasion

slab slip membrane sub-base subgrade

resistance, surface regularity •

Loading: type (wheel loads, leg loads from warehouse systems, …)


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•

Design life: how many years is the planned time of use of a floor

•

Ground conditions

These factors have an influence on the type of concrete used, the thickness of the slab, the type of coating used, placement of structural details as ts and the reinforcement. Further information on the requirements for slab construction can be found in the local technical recommendations that are available in each country: For further information on t design please refer to Chapter 9.

3.3. Summary of Products

Aggregate Mechanical Load moderate medium heavy impact resistant Coloured Versions

mineral

synthetic

metal

MASTERTOP 450

MASTERTOP 400K

corundum

x x

x x

x x

x x x x

x x x x

x x x

x x x

x

x

(x)

x

black*

(x)

x

Antistatic Properties

x

Processing/Application hand applied

x

spreader applied

x

Laser screed applied

MASTERTOP 201

MASTERTOP 200

MASTERTOP 800

MASTERTOP 135 LS

MASTERTOP 100

The following application procedures are described especially for the products in the table.

x x

x

x

x

x

x

x

x

x

x

x

x x x x (x) = selected colours available on request * MASTERTOP 201 is black in its appearance


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3.4. Application Procedures – How to install a proper dry shake floor For the installation of a dry shake floor there are two main possibilities: •

Manual dry shake application (by shovel or spreader): This application method is especially useful for floors < 1500 m². This method is entirely dependent on the skill and experience of the finishing team. Steps should be taken to ensure that suitably skilled operatives are provided to complete the installation of the floor satisfactorily.

•

Laser screed application: For large floors (from > 1000 m²) laser screed application provides a fast and efficient way of installing large floors in ONE application step.

For the installation of all dry shake floors the following topics should be noted: •

Conduct a pre-job conference well in advance with all involved parties

•

Have the right equipment on site

•

Fill out a technical service report

•

Check on concrete composition

•

Set out bags the day before to a calculated grid (for manual application only)

•

Plan enough time for all application steps

•

Site condition during construction can have a serious impact on the quality of the finished floor. When the floor is placed, it should be protected from wind, rain and extremes of temperature in the same way as normal construction. The temperature of the concrete at the time of delivery should be not less than +5°C and not exceed +30 °C

•

A floor incorporating a dry shake finish will usually be strong enough to carry foot traffic 15 - 24 hours after finishing. The cement continues to hydrate for several weeks and a concrete floor carries on drying out for many months or even a year. The rate of drying will strongly depend on the ambient environment within the building. During the drying time the floor surface may vary in tone and blotches may be visible caused by different rates of drying.

•

The floor should be protected after finishing as installation works spillage can influence the surface appearance or even damage the surface.


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3.4.1. Manual Application (e.g. with shovel) Step 1 Placing, consolidating and striking off concrete Concrete is placed at zero level with good planimetry. With least possible handling, deposit concrete between previously placed screed points. Move concrete into place with square-tipped shovels or other bladed tools; do not use rakes. Vibrators, when used, should be inserted vertically and should not be used to move concrete, but to consolidate. Step 2 Levelling concrete Strike off concrete with a true, wooden strike-off bar (straight edge). Immediately behind the strike-off operation, the concrete is further levelled and consolidated with a wooden bull float or in areas with limited access, with a wooden darby. This operation must be completed before any free moisture (bleeding) rises to the surface. Try to avoid bleeding by controlling the concrete composition and workability. Note: During hot, dry or windy conditions, consider spraying on the evaporation retardant MASTERTOP C 711CF (MASTERKURE 111CF). Step 3 Floating concrete (trowelling) If there is free bleed water on the surface, remove it prior to floating. A rubber squeegee dragged slowly over the surface is the best method. Concrete adjacent to forms, columns, pits, doorways and walls should be floated first because it stiffens faster than the concrete in the overall areas. Float the overall area as soon as the concrete will bear the weight of a finisher and a light trowelling machine, equipped with float blades, without digging it. See Picture on the right hand:

Concrete ready for floating

Step 4 First shake of MASTERTOP dry shake hardener Transfer the dry powder to a wheelbarrow of a size convenient for handling by men walking on the freshly floated surface. Apply the shake as soon as possible to areas adjacent to walls, forms, columns and doorways since these areas lose moisture very rapidly. Apply the shake evenly by hand or shovel to obtain a uniformly thick application over the surface. Immediately behind the first floating of the overall areas, as it proceeds, apply two thirds of the total shake specified evenly over the total surface. Application Manual Cementitious Flooring Products

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Step 5 Floating the first shake of MASTERTOP With wooden hand floats or power floats, float the shake on concrete adjacent to walls, forms, columns and doorways as soon as possible. Other finishers using power trowels with float blades should float the shake on overall areas as soon as the shake has absorbed moisture from the concrete beneath it (as indicated by darkening of the surface) and as soon as the float blades do not dig into the surface. Float just enough to bring the moisture through the shake and incorporate the plasticized shake into the surface of the slab, so that a cement paste layer remains. Time the floating operation so it will not be necessary to sprinkle water on the surface. Step 6 Second shake of MASTERTOP dry shake hardener As the floating of the first shake proceeds, follow immediately behind it with the remaining powder so it can absorb the moistured cement paste from the first shake at right angles to the first for even application. Step 7 Floating the second shake of MASTERTOP As soon as the second shake is absorbed by the moistured cement paste from the shake beneath it, as indicated by darkening of the surface, float the surface with a power trowel equipped with float blades. Additional floating The surface may be further compacted by a third or fourth power floating if time and setting characteristics of the concrete permit. Step 8 First trowelling When the surface stiffens further and loses some of its shine, it should be trowelled by hand or with power trowel, keeping the trowel blades as flat as possible without digging it. Step 9 Second / final trowelling When the surface “tightens” further it should be trowelled again by hand or with a power trowel. The blades may be raised slightly for this trowelling. When only a little paste clings to the trowel blade, a third, raised trowelling may be given to the floor. Pinholes and trowel marks should be removed in this hand trowelling operation. In case of coloured floors do not burnish trowel the floor, this may lead to discolouration. Note: During hot, dry or windy conditions, trowelling should be kept to the minimum necessary to obtain the right structure. Each delay in protecting the concrete surface with curing compound may cause problems. Application Manual Cementitious Flooring Products

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Step 10 Curing Just as soon as the surface will not be marred by the application, apply the suitable curing compound formulated by BASF Construction Chemicals for the type of surface and floor involved. For further information on the right choice of curing agent please see Chapter 8 Protective measurements The area should be barricaded after the curing compound is applied. As soon as the curing compound has dried, adequately cover the floor surface to prevent staining, discoloration or physical damage which may be difficult to correct. Alert other trades to the need for special protection against rolling or sliding heavy loads across the surface, oil drippings from pipe threaders, spillage of paint, plaster and mortar, acid washing of interior masonry walls, etc. Insure that the covering is not damaged during the progress of the job. Step 11 Sawing ts Sawing the ts should be carried out as soon as possible, without spalling the concrete. For further information on ts please see Chapter 9. Step 12 Application of sealant Apply appropriate t sealant according to the technical data sheet after concrete has hardened. 3.4.2. Spreader application For small to intermediate-sized concrete pours dry shakes can also be applied by using a spreader. The spreader is a wheeled unit that is pushed by hand or mechanically driven across the new but hardening concrete surface.

Simple mechanical spreader Application Manual Cementitious Flooring Products

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Spreading rate is governed by a discharge barrel in the base of the hopper body and relies on the skill of the operator to move the unit smoothly. Steps 1 to 3 are the same as for manual application (see page 13). Step 4 Spreader application of MASTERTOP dry shake hardener Transfer the MASTERTOP powder from the bags to the hopper of the spreader (approximately 2-3 bags maximum or even a big-bag for large spreaders – see photo below).

Motorized mechanical spreader Note: The spreader should be pre-calibrated to deliver the correct amount of material per to achieve the desired loading. This can be done by setting up a piece of plastic sheet 2 meters long and running the spreader over it. The material on the sheet can be weighed and the application rate adjusted. The application rate should be checked about every 200 m². The results should be kept for inclusion in the quality assurance records for the floor construction. Then continue with Steps 5 and 8 to 12 as described on pages 14/15.


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3.4.3. Laser screed application Laser Screed levelling and screeding machines have a huge advantage in the construction of large floor slabs. The machines enable large areas of concrete floor to be placed with few construction ts and high levels of surface tolerance. The main difference of this application for placing the dry shake surface hardener is that the material can be applied before the concrete has stiffened and application is possible in one step. Automatic spreaders are three axle machines with a counter-balanced hydraulically activated boom carrying a hopper. They are designed to work alongside the laser screed as part of a spreading system. The dry shake is dispensed by a variable discharge mechanism at the base of the hopper on a boom traversing above the surface of the concrete. The machine works off the sub-base and delivers the dry shake material directly to the freshly levelled concrete, enabling the dry shake to absorb the moistured cement paste. Be aware that bleed water is not allowed. The concrete composition and especially water/cement factor is chosen that the risk of bleed water is reduced /eliminated.

Laser Screed equipment: levelling machine (in front), spreading machine (behind)


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Step 1 Placing, consolidating and striking off concrete Concrete is placed in strokes or lanes at zero level with good planimetry. With least possible handling, deposit concrete between previously placed screed points. Move concrete into place with square-tipped shovels or other bladed tools; do not use rakes. Vibrators, when used, should be inserted vertically and should not be used to move concrete, but to consolidate. Strike off concrete with a true, wooden strike-off bar. Step 2 Levelling concrete Immediately behind the strike-off operation, the concrete is further levelled and consolidated with a laser screed or in areas with limited access, with a wooden darby. Step 3 Mechanical application of MASTERTOP dry shakes hardener The dry shake hoppers are filled manually with bagged material or big-bags. The spreading machine is then set up at the face of the concrete that has been levelled and compacted and the dry shake is then automatically spread evenly by a defined application rate.

Laser screed dry shake spreading Note: The specified application rate should be calibrated by filling the hoppers with dry shake material and performing a trial discharge over a weigh plate or by setting up a piece of plastic sheet 2 meters long and running the spreader over it. The material on the sheet can be Application Manual Cementitious Flooring Products

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weighed and the application rate adjusted. The application rate should be checked about every 500 m². The results should be kept for inclusion in the quality assurance records for the floor construction. The whole amount of specified material is applied in one step. Then continue with Steps 5 and 8 to 12 as described on pages 14/15.

3.5. Types of floors: The application procedures give a general instruction on the installation process. Depending on the requirements of the owner or architect additional steps should be considered and can lead to a special concrete floor. Comments are given in the following chapters. 3.5.1. Standard floors: Normal procedures as described in the chapters before.

3.5.2. Coloured floors Normal procedures as described in the chapters before, but take care of the following points: •

Finishing tools used on the coloured surface must be free of plain mortar or dirt, as these will contaminate or affect the final colour.

•

Coloured dry shake materials should never be applied to the surface of concrete until the concrete is properly consolidated and all free water has disappeared or been removed.

•

The greater the amount of coloured dry shake material applied, the greater will be the thickness of coloured surface mortar. Heavier shakes help prevent cement colour from being worked up through to the coloured surface during finishing. Overworking the surface during the early floating dilutes final colour.

•

The back and forth motion with a trowel often produces a slight difference in texture which is more apparent on a coloured floor than a plain floor.

•

Throwing water on a floor during finishing is a poor practice on any floor, and it produces a noticeable difference in shade on a coloured floor.

•

For final finish trowelling of coloured floors, use of stainless steel trowels is recommended. Finishers should use the same trowelling motion and blade angle as they move over the floor. Overworking the surface during final trowelling can cause spotty colour.

•

A coloured floor surface should not be burnish trowelled; that is, hard trowelling after there is no longer any paste left for the trowel. Burnishing coloured floors "burns" the colour, often


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resulting in mottling, darker shades becoming much lighter and light or pastel colours becoming darker. •

Coloured floors must not be cured with paper, polyethylene, ponding, straw, damp sand or burlap as this will cause efflorescence stains. Use a clear sealer or matching pigmented wax or sealer designed for this purpose.

•

After curing is applied, coloured floors should be covered with paper or polyethylene to further protect it from paint, oil, .abrasion, etc. from the other trades.

Observing these precautions will help the contractor produce coloured floors that have a uniform colour of the desired shade.

3.5.3. Aesthetic floors: In general the same procedures as described for coloured floors before, but everything has to be done even more accurately and preferably by highly skilled and experienced applicators. The concrete quality, its placing and levelling has to be very exact and is the key to success. Take care not to leave any footprints or wheel marks in the concrete. The spreading should be carried out either automatically (with laserscreed equipment) or by spreaders that run on long wooden boards in order to not leave wheel and foot marks. Should a foot / wheel mark appear despite all precautions, it is essential to smoothen it within 5 minutes – otherwise it will remain visible! Application thickness of the dry shake has to be as uniform as possible. Finishing of the floor should be done preferably in presence of the owner/customer and continued until he agrees on the surface appearance.

3.5.4. Light reflective floors: All things mentioned for coloured floors remain valid here as well. Additionally, since the light reflective dry shakes contain white cement, care must be used in applying it on the concrete surface. Application at the wrong time may produce a muddy diluted effect if the dry shake is applied too early in the concrete placement. Typically the slab should have no, or very minimal, residual bleed water present and the slab should be floated prior to the application of the dry shake in case of hand/spreader application. The use of a mechanical spreader is helpful in applying the material in a uniform relatively thick application rate. Proper floating and techniques must be employed with care taken to maintain a clean uncontaminated surface. Use stainless steel pans for floating as they will not cause discolouration of the dry shake. All tools have to be very clean and non-rusty at all. Workers


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are using plastic boot wrapping when machining the surface of the slabs. A final finishing hand trowel is provided on the surface taking care not to burn the slab surface and discolour it. Hand trowelling is often employed during the final slab finishing operation with the abrasion resistance coming from dry shake hardener. Protection of the slab involves two concerns. The proper curing of the slab can be accomplished with a liquid membrane-curing compound with no yellowing qualities. Best performance is when these materials are back rolled with a short nap roller after spraying on the surface. This also produces a more uniform distribution of the curing compound on the surface to assume more uniform hydration and subsequent drying of the surface after curing. During construction good housekeeping techniques should be used to protect the floor. Care should be taken to avoid a highly polished surface that does not produce enough diffusion of the light. The glare of these surfaces is readily seen—from even a dark pigmented concrete slab. This glare can produce considerable eye fatigue when light reflects off of the surface of the slab.

3.5.5. Antistatic floors – Installation of MASTERTOP 201 Antistatic floors need to be installed under the following conditions: -

in areas where solvent containing products are manufactured, handled and stored

-

in areas where there are explosives or explosive dusts are handled

-

in areas where static charges are continually being generated by continuous processes

MASTERTOP 201 is a pre-mixed, ready to use product designed to be applied as a dry shake by shovel or spreader over freshly placed concrete to provide an iron armoured spark resistant floor surface. Note: due to the special conductive ingredients in MASTERTOP 201 this product is black coloured. The application is carried out as regular dry shake surface hardeners with the following additions: •

Electrical circuit installation prior to concrete

It is very important to install an electrical grounding system for use with the static disseminating and spark resistant metallic floor finish MASTERTOP 201. Use one ground rod or ground stud per 45 m² (typically every 6.5 x 6.5 m) – see graphics on next page. It is a must to place an electrical connection to the metallic conductors. In many installations, the building ground and earth ground are connected to each other by heavy copper cables.


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Typical floor area showing the location of ground rods / studs with one for each 45 m² of floor

Grounding systems details (Drawings not to scale). •

Curing

Just as soon as the surface will not be marred by the application, apply the special curing compound MASTERTOP C 762 (MASTERKURE 620). Application Manual Cementitious Flooring Products

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4. Pumpable products 4.1. Concrete mix design For requirements of concrete when applying MASTERTOP P products fresh in fresh please see Chapter 3.1.

4.2. Slab construction For information on slab construction please see Chapter 3.2.

4.3. Summary of products The MASTERTOP P product range are ready-to-use pumpable, pourable and screedable high strength cement based overlays for floors for indoor and outdoor applications. They are available with different durable aggregates (see table below) to meet the different requirements on abrasion resistance for cementitious floors. The products have the following features: -

economical, ready-to-use, pumpable cement and hard aggregates based flooring overlays, that harden free of bleeding at any consistency: from flowable / pourable to damp pack.

-

the mixed products can be pumped without separation with high-yield mortar pumps (screw pumps).

-

can be easily poured and distributed.

-

retain good workability for at least 30 minutes at 20 to 25°C.

-

by using a cement based bonding slurry good adhesion will and no blistering will be ensured, when applied on existing (hardened) concrete.


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4.4. Application procedures General Information MASTERTOP 135 P MASTERTOP 200 P MASTERTOP 450 P Aggregate

mineral

metal

corundum

x x

x x x x

x x x

Coloured Versions

x

x

x

Processing/Application on fresh concrete

x

x

x

on old concrete

x

x

x

Layer thickness

5 – 15 mm

5 - 15 mm

5 – 15 mm

Mechanical Load moderate medium heavy impact resistant

For further data please refer to the technical data sheets. 4.4.1. Installation onto freshly poured concrete The fresh concrete is placed at the level depending on the application thickness of MASTERTOP P to obtain the required top surface level. This application thickness is typically between 5 to 15 mm. Steps 1 to 3 are the same as for manual application of dry shakes (see page 13). Step 4 Mixing of the product Measure the necessary mixing water and put ¾ of the water required in the mixer first, than slowly and steadily add the powder. Mix until smooth (2-3 minutes) in a concrete mixer and/or mechanical mixer (max. 400 rpm). Add the rest of the water and continue to mix for at least 2 more minutes. Use of ice water to produce mixed mortar temperatures of +20°C to +35°C will reduce water required for a given consistency and increase strength and working time accordingly. Do not re-temper material by adding water or remixing after it stiffens. Start the mixer and add MASTERTOP P. Continue mixing until a homogenous and lump-free mortar is obtained (total of 5 minutes). Other types of mixers (self feeding etc…) where the dry powder is added continuously and water is mixed during the feeding process are possible; consult your local BASF Construction Chemicals representative in this case Application Manual Cementitious Flooring Products

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Note: - Do not add cement, sand or other materials to the mix! - Do not use the contents of packages that are damaged or broken. - Use one or more mixers to permit mixing and placing operations to proceed simultaneously without interruption. - DO NOT MIX BY HAND! - Mix with clean tap water only. Step 5 Placing of material The mixed MASTERTOP P product is applied onto the floated concrete. Mix and place flooring overlay as close as possible to the place being treated. Have sufficient manpower, materials and tools to make mixing and placing rapid and continuous. The material shall be poured continuously to a layer thickness of minimum 5 15 mm max. Consult BASF Construction Chemicals in case of higher layer thickness. MASTERTOP P grades will flow out horizontally on application. Step 6 Levelling of material The surface should be gone over with a straight edge to give it the best possible de-aeration. The setting material must not be diluted with additional water or fresh mortar. In the event of low humidity, high room temperature, direct sunshine or draughts, the surface should be covered in order to protect it from drying too quickly, once it is dry enough to be stepped on. Step 7 First floating As soon as the mortar has sufficiently dried, start the floating process. With wooden hand floats or power floats, float the mortar on concrete adjacent to walls, forms, columns and doorways as soon as possible. Time the floating operation so it will not be necessary to sprinkle water on the surface. Step 8 Additional floating The surface may be further compacted by a third or fourth power floating if time and setting characteristics of the concrete permit. Step 9 First trowelling When the surface stiffens further and loses some of its sheen, it should be trowelled by hand or with power trowel, keeping the trowel blades as flat as possible without digging it.


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Step 10 Second / final trowelling When the surface “tightens” further it should be trowelled again by hand or with a power trowel. The blades may be raised slightly for this trowelling. When only a little paste clings to the trowel blade, a third, raised trowelling may be given to the floor. Pinholes and trowel marks should be removed in this hand trowelling operation. In case of coloured floors do not burnish trowel the floor, this may lead to discolouration. Step 11 Curing Just as soon as the surface will not be marred by the application, apply the suitable curing compound formulated by BASF Construction Chemicals for the type of surface and floor involved. For further information on the right choice of curing agent please see Chapter 8 Step 12 Sawing ts Sawing the ts should be carried out as soon as possible, without spalling the concrete. For further information on ts please see Chapter 9. Step 13 Application of sealant Apply appropriate t sealant according to the technical data sheet after concrete has hardened. 4.4.2. Installation on existing concrete Step 1 Preparation of the substrate The substrate must be clean, healthy and sound. Remove all traces of previous coatings, laitance, oil, curing compounds, grease, dirt, cement skin, organic growth or any other contaminants which may adversely affect the bond. To achieve a good bonding surface, the use of grit blasting, shot blasting or high pressure water cleaning is recommended. Step 2 Water saturation Saturate the cleaned foundation for at least 6 hours, preferably 24 hours. Just before applying the bonding slurry remove all free water. Step 3 Application of bonding slurry On the water-saturated substrate that is free of excess water the mixed bonding slurry (e.g. MASTERTOP 500) is immediately applied using a hard broom. Work it thoroughly onto the surface (see also picture on page 29). Do not allow the bonding agent to dry!


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Step 4 Placing of material The ready mixed MASTERTOP P product (please see Step 5 on page 27) has to be applied onto the bonding agent fresh-in-fresh. Mix and place flooring overlay as close as possible to the place being treated. Have sufficient manpower, materials and tools to make mixing and placing rapid and continuous. The material shall be poured continuously to a layer thickness of minimum 5 - 15 mm max. Consult BASF Construction Chemicals in case of higher layer thickness. MASTERTOP products will flow out horizontally on application. Then continue with Steps 6 to 13 as described on pages 25/26.

5. Screedable Topping – MASTERTOP 210 / 230 MASTERTOP 210 and MASTERTOP 230 are ready to use, pre mixed floor toppings based on hydraulic binders, special treated metal particles and selected dispersing and hardening agents. General information: MASTERTOP 210

MASTERTOP 230

Layer thickness

5 – 15 mm

15 – 30 mm

Colours

6 colours on request

Natural (dark grey)

For further data please refer to the technical data sheets.

5.1. Application procedures 5.1.1. Installation onto freshly poured concrete The fresh concrete is placed at the level depending on the application thickness of MASTERTOP 210 / 230 to obtain the required top surface level. •

Concrete mix and Slab design: see Chapters 3.1 and 3.2.

Steps 1 to 3 are the same as for manual application of dry shakes (see page 13). Step 4 Mixing of Mortar Measure the necessary mixing water and put it into the mixing vessel. Start the mixer and add MASTERTOP 210 / 230. Continue mixing until a homogeneous and lump free mortar is obtained (total of 5 minutes). Mix according to the instruction in the technical data sheet. Use one or more mixers to permit mixing and placing operations to proceed simultaneously without interruption.


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Note: - Do not add cement, sand or other materials to the mix! - Do not use the contents of bags that are damaged or broken. - DO NOT MIX BY HAND! - Mix with clean tap water only. Step 5 Application The mixed MASTERTOP 210 / 230 is applied on the floated concrete. An even and uniform spread is recommended. Level the MASTERTOP 210 / 230 mortar by the screeding method. Mix the product as close as possible to the place of installation. Have sufficient manpower, materials and tools to make mixing and placing rapid and continuous. Then continue with Steps 6 to 13 as described on pages 25/26. 5.1.2. Installation on existing concrete Step 1 Surface preparation The old surface needs to be carefully prepared before the application of MASTERTOP 210 / 230. The substrate must be clean, healthy and sound. Remove all traces of previous coatings, laitance, oil, curing compounds, grease, dirt, cement skin, organic growth or any other contaminants which may adversely affect the bond. To achieve a good bonding surface, the use of grit blasting, shot blasting or high pressure water cleaning is recommended. Step 2 Water saturation of concrete The roughened concrete shall be saturated with water for at least 6 to 24 hours, before MASTERTOP 210 / 230 is applied. Remove the excessive standing water before proceeding to the next step. Step 3 Application of bonding slurry On the water-saturated substrate that is free of excess water the mixed bonding slurry (e.g. MASTERTOP 210/230 mixed in a slurry consistency or MASTERTOP 500) is immediately applied using a hard broom. Work it thoroughly onto the surface. Do not allow the bonding agent to dry!


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Application of MASTERTOP 500 bonding slurry Step 4 Application The ready mixed MASTERTOP 210 / 230 (for mixing please refer to Step 4 on page 27) is applied wet-in-wet onto the fresh bonding slurry. Level the mortar by the screeding-method. Mix the product as close as possible to the place of installation. Have sufficient manpower, materials and tools to make mixing and placing rapid and continuous.

Installation of MASTERTOP 230 on existing concrete (using a floor surface vibrator) Then continue with steps 6 to 13 as described on pages 25/26. Application Manual Cementitious Flooring Products

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6. Trouble shooting 6.1. Bleeding of concrete Avoid extensive bleeding of concrete as it will make the dry shake too wet. If the concrete shows bleeding even after floating, remove bleeding water with a squeegee or a water hose (see picture below) directly before spreading the dry shake.

Removal of bleed water with hose before applying dry shake

6.2. Wind Wind is an issue especially for all external application and those installations where wind can attack, e.g. ware house ramps, hangars with big open doors etc. Try to avoid wind if somehow manageable, especially during application and at least for the next 24 hours. Wind can cause too quick evaporation and hence lead to all kind of damages like cracking, spalling but also problems of the concrete curing itself. In case wind cannot be controlled/excluded, apply the evaporation retardant MASTERTOP C 711CF (MASTERKURE 111CF) on the fresh concrete.


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6.3. Dry shake is applied too early If dry shake is applied too early, it is often mixed with larger amounts of surface water. This usually results in problematic trowelling during which dry shake sticks to trowel-machine blades. As a consequence, local problems with flatness often arise. If dry shake is applied directly into surface water, there is another danger that it will segregate and the surface of finished floor will separate and/or delaminate.

6.4. Dry shake is applied too late If dry shake is applied too late, the concrete slab does not have enough water to moisten it and delamination can occur. The correction of details by hand is very difficult in such cases. Note: most of the time sprinkling water during the trowelling process is done, but this is not recommended.

6.5. The floor is uneven in colour or even grey In such case the dry shake was very probably applied too early (on soft concrete surface with high content of water), or surface water had not been removed. Also too low dosage rates of dry shakes will mix the material to with concrete from below, and this causes the low colour intensity. Propose light coloured concrete when also light coloured MASTERTOP is used. Be careful to control the concrete composition prior the choice of the MASTERTOP colour.

6.6. Potential defects in concrete floors •

Delamination: This effect occurs when part or all of the dry shake finish fails to bond with the base concrete. The thickness of the delaminated layer depends on the application rate of the dry shake and the density of the aggregate. Patterns of hairline cracks may be visible and the surface might slightly lift and sound hollow when tapped with a metal tool. It can be on a few isolated spots on larger patches.

•

Cracking: Cracks are not uncommon especially with large tless floors.

•

Crazing: Excessive floating or trowelling of a slab surface can produce a layer of laitance which tends to dry more quickly than the inner mass. The resulting tensile forces in the surface can cause a fine crazing pattern. Because the cracks are narrow and shallow crazing normally does not need to be repaired.


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•

Pinholes and pop-outs: They are usually less then 5 mm in diameter and are caused by particles of fine aggregates flicking out during trowelling or failure of some of the dry shake constituents. They are unlikely to affect floor durability of interfere with traffic and any repair may be more noticeable than the original defect.

Further details on trouble shooting will be given in the "Cementitious Floors Problem Solving Guide" that will be available shortly.

7. Repairs Defects in concrete floors may be repaired in several ways and are described in the following section. It must be recognized that a repaired area cannot be hidden easily as an exact colour match can not be achieved. The appearance and effectiveness of the repair will be most satisfactory if square or rectangular areas are used, the edges of the repair are parallel to the slab edges and ts, the areas to be repaired are saw cut vertically and the repair surface is finished flush with the adjacent floor.

7.1. Local Repair of ts and Corners ts are normally the areas in a floor that are subject to most mechanical impact due to hits. Therefore they are also the parts of a floor that are damaged first. The following part describes the process to repair ts and corners with suitable repair products. Step 1 Removal of damaged areas Saw cut damaged areas vertically and remove the concrete. The old surface shall be carefully prepared before the application of the repair mortar. Chip old concrete to the desired depth with a chipping hammer or mill until a good, solid and clean surface is obtained. All loose particles that may negatively affect the bonding as well as oil, grease, cement laitance, dust and other foreign matters shall be removed. Step 2 Water saturation of concrete The roughened concrete shall be saturated with water before any bonding slurry is applied. Remove the excessive standing water before proceeding to the next step. Step 3 Application of bonding agent On the water-saturated substrate that is free of excess water the mixed bonding slurry (e.g. repair mortar mixed in a slurry consistency or MASTERTOP 500) is immediately applied using a hard broom or a suitable brush (e.g. EMACO Nanocrete Brush). Work it thoroughly onto the surface. Do not allow the bonding agent to dry! Application Manual Cementitious Flooring Products

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Step 4 Mixing of Mortar Measure the necessary mixing water and put it into the mixing vessel. Start the mixer and add MASTERTOP 230. Continue mixing until a homogeneous and lump free mortar is obtained. Mix according to the instructions given in the technical data sheet. Step 5 Application The mixed repair product is applied on the prepared concrete . An even and uniform spread is recommended. Level the mortar by the screeding-tamping method. Step 6 Floating As soon as the mortar has sufficiently dried, start the floating process. In small areas wooden hand floats may be used to float the mortar. Step 7 Curing Just as soon as the surface will not be marred by the application, apply the suitable curing compound formulated by BASF Construction Chemicals.

7.2. Local repairs in existing concrete substrate or damaged final floors General remarks: BASF Construction Chemicals offers various repair products for local patch repair. To offer the right product it is essential to know the needs of the customer on the specific site. Questions to be asked: Is the main need to repair the damaged area as quickly as possible (in order to minimize e.g. shutdown times) or is it more important to match the existing floor optic? The latter will be for sure essential for coloured floors. 7.2.1. Universal floor repair options PLEASE NOTE: might result in a different colour appearance of the repaired area! Repair Products: •

EMACO Fast products: allow fast repair in thickness from 5 to 100 mm. Repaired area can be opened to traffic within 2 to 3 hours.

•

MASTERTOP 560 (Fluid): allows fast repairs from 10 to 80 mm. Repaired area can be opened to traffic the next day.

For further information on the properties and application of the products please consult the corresponding technical data sheets.


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7.2.2. Repairs ("like-with-like"), limited to repairs < 20 mm thickness To repair damaged floors, where the optical appearance of the surrounding area shall be matched and the layer thickness of the replacement is below 20 mm, the corresponding MASTERTOP P product should be used. However, especially when coloured floors are installed, the repaired area will probably remain visible as slight colour variations cannot be prevented. For the application instructions please refer to Chapter 4.4.2. “Application on existing concrete”.

8. Curings What is curing? Curing means to treat the concrete so it retains the water for the cement hydration. Curing is the process of controlling the rate and extent of moisture loss from concrete during cement hydration. It takes place after it has been placed in position, thereby providing time for the hydration of the cement to occur. Since the hydration of cement does take time – days, and even weeks rather than hours – curing must be undertaken for a reasonable period of time if the concrete is to achieve its potential strength and durability. Curing may also encom the control of temperature since this affects the rate at which cement hydrates. Concrete that is allowed to dry out quickly also undergoes considerable early age drying shrinkage. Inadequate or insufficient curing is one of main factors contributing to weak, powdery surfaces with low abrasion resistance. The durability of concrete is affected by a number of factors including its permeability and absorbance. Broadly speaking, these are related to the porosity of the concrete and whether the pores and capillaries are discrete or interconnected. Whilst the number and size of the pores and capillaries in cement paste are related directly to its water-cement ratio, they are also related, indirectly, to the extent of water curing. Over time, water curing causes hydration products to fill, either partially or completely, the pores and capillaries present, and, hence, help to reduce the porosity of the paste. When to apply curing? Immediately after the surface (at least within 2 hours and no later than 6 hours after finishing the floor) has been finished by trowelling and has hardened sufficiently the concrete should be cured. Curing should be continuous and effective for at least seven days, longer in colder weather. Draughts and cross winds must be avoided by enclosing or screening the finished floor.


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How to achieve curing? Curing can be achieved by: •

spraying of MASTERTOP C liquid curing products onto the surface or

•

waterproof sheets kept in close with the surface. Sheets should overlap at the edges and be securely fixed so that they don't move.

For a choice on appropriate curing agents please see the following table:

Curing Selection Guide MASTERTOP C 713

MASTERTOP C 714

MASTERTOP C 715

MASTERTOP C 762

MASTERTOP C 781

MASTERTOP C 782

Solvent containing dispersion


Wax-based, solvent containing

Conductive wax-based, solvent containing


Water based paraffin

YES

YES

NO

NO

YES

NO

Non-coloured (natural) floors

++

++

++

Only conductive

++

++

Coloured floors

-

++

++

-

-

+

Light reflective floors

-

+

+

-

-

+

Not to use on coloured or conductive floors.

Not to use on conductive floors.

Curing and waxing at the same time; not to use on conductive floors.

Special curing for conductive MASTERTOP 201 floors.

Not to use on conductive or coloured floors.

Not to use on conductive floors.

NO

YES

YES

NO

YES

NO

MT 100

+

+

+

-

+

+

MT 135 LS

+

+

+

-

+

+

MT 200

+

+

+

-

+

+

MT 201

--

-

-

+

--

--

MT 400K / MT 450

+

+

+

-

+

+

MT 800

+

+

+

-

+

+

MT 135 P

+

+

+

-

+

+

MT 200 P

+

+

+

-

+

+

MT 450 P

+

+

+

-

+

+

MT 210

+

+

+

-

+

+

MT 230

+

+

+

-

+

+

Description Sprayable Type of Floor

Remark

Overcoatable Product


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Note: MASTERTOP C 711CF (MASTERKURE 111CF) is no curing but an evaporation retardant and finishing aid that helps to produce high quality concrete flatwork. Hence this product is treated in Chapter 3.1. Concrete.

How to apply MASTERTOP C curings? Apply a thin, equal layer by sprayer (garden type), brush (shorthaired) or roll. For quantities needed per m² please consult the technical data sheets of the different products. The products should be applied at temperatures above +5°C. It is important to apply an equal layer of the product otherwise the floor will have a spotted appearance after a while. Immediately after application, the concrete has a shiny appearance that makes it easy to see which part has been treated and double layers can be avoided.

9. ts 9.1. Types of ts 3 types of ts can be distinguished: a. Expansion (setting) ts b. Isolation ts c. Contraction ts

Types of ts Application Manual Cementitious Flooring Products

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a. Expansion (setting) ts Expansion ts cut the slab completely in a vertical way, so the cut parts can move independently. Expansion ts have 2 functions: different vertical movement of parts of the structure and horizontal movement due to temperature extension/contraction. An example for the design of an expansion setting t can be found in the following technical drawing.

Expansion (setting) t 1. reinforced concrete slab

8. elastic t filler MASTERFLEX 474

2. MASTERTOP dry shake / topping

9. back filler rod, e.g. MASTERFLEX backer rod

3. dowel sleeve

10. compressible t plate (e.g. styrene plate)

4. steel dowel

11. spacer reinforcement

5. dowel spacer

12. PE foil, thickness 0.2 mm

6. wire mesh / welded wire mesh / rebar

13. stabilised substrate (e.g. lean concrete)

7. edge profile or MASTERTOP plastic mortar

N.B.: dimensioning of reinforcement and dowels follows load study


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b. Isolation ts Isolation ts isolate the concrete slab from other construction parts (e.g. walls, columns…).

Isolation t at walls

ts at columns Isolation ts must me installed at fixed parts (walls, columns...) over the full thickness of the slab. They are to be filled with a compressive material.

c. Contraction ts Contraction ts are cut in the fresh slab, 1 to 2 days after pouring. The ts are cut to ¼ - ⅓ of the thickness of the slab, upper reinforcement is to be cut. The saw cut must be 3 - 5 mm wide (see detail drawing on next page).


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Details of a contraction t 1. reinforced concrete slab 2. MASTERTOP dry shake / topping 3. wire mesh / welded wire mesh / rebar 4. spacer reinforcement 5. PE foil, thickness 0.2 mm 6. saw cut, width 3 – 5 mm, depth ¼ to ⅓ of slab's thickness, upper reinforcement has to be cut 7. elastic t filler MASTERFLEX 474 8. stabilised substrate (e.g. lean concrete) N.B.: dimensioning of reinforcement and dowels follows load study


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9.2. MASTERTOP armoured ts Deteriorated, rutted ts in floors are the number 1 problem in commercial and industrial floors. ts on the floors are the critical points in concrete floor due to the heavy impact from fork lift trucks or steel wheeled trolleys. Iron armoured t will prolong the overall life of the concrete floor. The next paragraphs will outline how MASTERTOP armoured ts can be installed. Remove any bleed water at edges before proceeding with ts. The concrete at the ts to be armoured should be cut down and removed to a depth of 12mm at the t line or form, tapering back to surface level at 100mm from the t line. This area should then be floated with a wooden hand float working up sufficient paste at the surface to assure an integral bond of the mortar to the fresh slab. Mix MASTERTOP with enough water to obtain a stiff mortar consistency. Place, level off and wood float the mortar while keeping the float perpendicular to the t at all times. Do not pack the t, use only enough material to fill the void.

Details of special armoured (left) and construction t (right) made with MASTERTOP mortar When armouring control ts, it is imperative that the placement of the mortar be on the centre line of the designed t location. Once the exact location of the t centre line is determined and can be visually followed across the slabs (either by string or chalk line), bridge the slab approximately 150mm to the side. Working from the bridge platform the t is treated as previously described. The application rate is approx. 3.3 kg per lineal meter per one side of t. Two sides (as shown above) are approx. 6.6 kg per lineal meter.


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9.3. MASTERFLEX 474 MASTERFLEX 474 is a single-component, non-sag, tough, pick-resistant, high modulus polyurethane t sealant for floors and walls. The product is ideal for: – Floor connection and expansion ts in buildings and civil structures – Pedestrian and traffic areas (e. g. car decks / parks) – Warehouse and production areas – Medium chemical exposure areas (e. g. canteen kitchens, garages) – Public buildings subject to possible vandalism e. g. prisons and police cells, schools, libraries – Areas constantly submerged in water (use correct primer!) MASTERFLEX 474 provides the following features: – Single component – easy to use – For walls and floors – Good mechanical and chemical resistance – Excellent adhesion to most substrates even without priming – Robust tough seal with high pick / vandalism resistance – Good weathering and ageing resistance provides high durability and long service life – Short skinning time – early resistance to rain and limited risk of dirt pick up – High elastic recovery – No residual tackiness and non corrosive – Available in colours grey, white, black, brown and beige •

Application Procedure for t sealant MASTERFLEX 474

Step 1 Preparation of Substrate The substrate must be clean, sound and dry. All traces of dust, oil and other dirt must be removed. A minimum direct tensile adhesion strength of 1.5 N/mm² of the substrate is required. For correct installation of the t sealant it is essential that bond breaker tape or polyethylene closed cell backer rod is used to regulate t depth and prevent three sided adhesion. On well prepared dry, sound concrete older than 28 days, masonry or metal or glass surfaces MASTERFLEX 474 does not require a primer.


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Step 2 Application The product is supplied ready for application. Cut open the foil sausage (or the nozzle) at one end and place in a manual or pneumatic gun and apply immediately. The product should be tooled smooth with a spatula or with non-alcoholic liquid to create a concave surface free of bubbles. It can be applied directly both horizontally and vertically.

MASTERFLEX 474 (light grey) applied in a horizontal expansion t

Application of MASTERFLEX 474 (light grey) in a wall/floor connection (isolation) t For more details please refer to the MASTERFLEX Sealants brochure and/or the technical data sheet. Application Manual Cementitious Flooring Products

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10. Tools The choice of the most suitable tools and the correct use of well maintained equipment is one important factor for the successful installation of cementitious flooring products.

Please find an exemplary for concrete placement equipment (e.g. laser screed equipment) below: •

Somero Enterprises, Ltd. European Office Broombank Road Chesterfield Trading Estate England S41 9QJ www.somero.com

11. Recommendation on Job Site Organisation 11.1. Safety and precautions All MASTERTOP cementitious flooring products contain cement which may cause irritation. Avoid with eyes and prolonged with skin. If occurs, wash thoroughly with water and call a doctor. Keep product out of reach of children. Consult the Material Safety Data Sheet of the corresponding product for more details.


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11.2. Field Service BASF Construction Chemicals recommends that the requests the services of the local representative for a pre-job conference to carefully plan each step of the installation.

11.3. Job Site Organization Setting up, pouring and finishing a concrete floor does not just happen. It takes some careful planning. The following list should give some recommendations for installing successfully concrete floors. •

Conduct a preconstruction meeting with all the parties involved to set up a well-executed installation and placement plan.

•

Facilitate on-site communication between suppliers and contractors

•

Require adherence to specified tolerances and reject defective products

•

Insist on a clean work site with well organized storage areas

•

Use skilled operators and tradesmen utilizing new tools and maintained equipment

•

The correct timing is crucial for installing high quality floors, therefore plan sufficient time for placing of concrete (include time of the day, weather, temperature,…), time for floating and all the other application steps.

•

Plan for enough people to carry out a project

12. Maintenance BASF Construction Chemicals MASTERTOP cementitious floor surfaces installed in your facility have far greater surface density than plain concrete and thus increasing / improving the resistance to penetration by oil, grease, hydraulic fluids and many industrial chemicals. This allows much easier and less expensive cleaning because the absorption of water and cleaning agents is reduced. While the floor surfaces in your facility provide increased wear resistance and a denser, easier to clean surface, a continual cleaning program should not be ignored. Generally, good housekeeping practices such as cleaning up spills when they occur and cleaning the entire floor surface on a regular basis will maintain and enhance the colour appearance and - if applicable - the light reflective qualities that you desire. While general and periodic cleaning will be the bulk of your maintenance program, other forms of dirt and stains such as tire marks, oxidation, grease, paint etc will demand special cleaning agents and techniques. BASF Construction Chemicals stands behind our products and are always available to help with any maintenance questions or concerns you may have.


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Some of the cleaning chemicals mentioned herein are classified toxic by the manufacturer, thus precautions must be taken when using and disposing of these products. Local regulations should be checked and followed. •

General Cleaning

For general cleaning, the material that has been used with success, is an all purpose high alkaline detergent. Scrubbing the floor with this type of detergent and a power floor scrubber will offer the best results for periodic cleaning. •

Curing Compound Removal

The use of a BASF Construction Chemicals approved curing compound is of utmost importance for curing 'dry-shake' floor surfaces. Coloured concrete surfaces cured using curing paper, plastic sheeting, wet sand or pending may develop a white efflorescence on the surface. This stain is almost impossible to remove without damaging the surface itself. Acids such as acetic or muriatic will remove efflorescence stains, but some etching of the cement matrix will take place. This is undesirable for these industrial floor surfaces. To remove the efflorescence from the surface of those coloured floors that have not been cured with one of the MASTERTOP C (MASTERKURE) curing products, we suggest the use of sulfamic acid (H2NSO2OH), sometimes called amidosulfonic acid. This material can be purchased wherever chemical supplies are available and often in masonry or paint supply stores. Sulfamic acid should be purchased in powder form and dissolved in water. A solution below 10% should not etch the cement matrix. Always start with a trial solution of 5% or less, and gradually increase concentration of the solution as necessary to do the job, but always staying below 10%. After the efflorescence stains have disappeared, the surface should be damp mopped clean. During this entire operation, avoid the use of excess water or solution. Do not flood the floor. After physically removing as much water as possible, quick dry the surface and immediately follow with an application of a MASTERTOP C (MASTERKURE) product. If a curing compound is used and it is desired to remove it after the curing 28 days process there are products and procedures that can make this task as easy as possible. While some MASTERTOP C (MASTERKURE) types are easier to remove than other curing compounds, it may still be troublesome if the compound has been ground into the surface by repeated traffic. Keep in mind that all wax based curing compounds can be removed with a low solvent cleaner.


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While particular solvents can attack/destroy this curing compound, procedures can be adapted to specific needs. Although composition and bond of the material must be scrubbed off and immediately removed or vacuumed from the surface. Cleaning using a power scrubbing machine with wet vacuum is recommended, because it is important not to leave the products or water on the surface for extended periods of time. This prevents slippery conditions, re-adhesion as well as surface oxidation. When using these strippers in conjunction with a power scrubbing machine please be aware of the different types of pads to be used. All pad manufacturers try to maintain a continuity of colour, however this does not hold true. As a general rule the pad colours are as follows: - Black - stripping - Green - scrubbing - Red & Blue - buffing While black stripping pads should not be used on light reflective floors they are very effective on natural and dark coloured MASTERTOP floors. The green scrubbing is the preferable pad for light reflective floors; the buffing pads are also acceptable. •

General Cleaning and On-Going Maintenance

The type of cleaning solutions and compounds are extremely important in regard to their use on metallic floors. In areas subject to frequent cleaning, all maintenance products should be a high alkaline composition. It has been found that the use of high alkaline cleaning agents has either caused or increased the potential for surface oxidation on metallic floor surfaces. Weekly or even daily cleaning using a power scrubbing machine with wet vacuum is recommended, because it is important not to let the products or water sit on the surface for extended periods of time. This prevents both slippery conditions as well as surface oxidation. •

Rubber Tyre Mark Removal

A major problem in maintaining industrial floors are the tyre marks from lift trucks. These marks become more apparent and troublesome when a light reflective floor is involved because they reduce the energy saving qualities of the floor surface. The most common lift truck tyres are made from a universal rubber compound. This type of tyre will leave marks on concrete floors and are especially unsightly on light reflective surfaces. There are two types of "non-marking" tyres available and should be used where tyre marks will become a problem. "White" tyres are made from synthetic rubber with white silica gel or resin instead of carbon. The "white" tyres have a grey white appearance, reportedly cost about 25% more than universal rubber tyres and have about 90% of the life of universal tyres. These


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"white" tyres can have a heat build up problem when running fast and/or long distances. If heat builds up, the load capacity is somewhat reduced. This type of tyre leaves a white dust which supposedly does not adhere to the floor surface and this can be swept up during general cleaning operations. The traction is about the same as universal tyres. Polyurethane tyres are shiny black in appearance and cost about twice as much as universal rubber tyres. Reportedly, the polyurethane tyres wear three times longer than universal tyres. Polyurethane tyres have heat build up when running fast or long distances. These tyres are sometimes grooved for heat dispersion. If the heat builds up, the load capacity of the tyre is reduced. This type of tyre will leave a black residue that does not stick to the floor, again allowing the residue to be swept up during the cleaning process. The traction is less than that of the universal tyre or "white" tyre. Spinning can be a problem, particularly if there is liquid on the floor. Most of the major tyre manufacturers produce a line of non-marking tyres. When universal rubber tyres are in service and tyre marks do become a problem, there are numerous products on the market that claim the ability to remove them. Whenever trying a new material, do a small test in an inconspicuous area in the case of metallic floors, if there is any questions as to the effect on the iron aggregate, have the material tested and/or get assurances from the manufacturer. •

Grease & Oils Stain Removal

Again, a regular housekeeping program will enhance the appearance of your floor. However, as oil and grease stains become evident, many cleaning options are available. In case of huge and long-term exposure of grease and oil, remove it with PCI Entöler (PCI De-greasing Agent). •

Oxidation Removal

Minor surface oxidation will occasionally appear on Light Reflective MASTERTOP 200 surfaces. It must be kept in mind that there is a major difference between surface oxidation and oxidation that occurs due to impure iron aggregate. Although the occasional minor surface oxidation possible with Light Reflective MASTERTOP 200 will not hamper the serviceability or durability of the floor, at times it is visually objectionable and mist be removed. While acid etching is after used to prepare concrete for condign toppings etc, other precautions must be considered when etching a metallic surface. The by-products of HCl acid on iron are explosive hydrogen (H2) and toxic H2S. It is suggested that if acid is to be used where metal is involved, that it be a dilute concentration of phosphoric acid. Another advantage to the phosphoric solutions is that it should not be flushed off. Therefore, a weak solution could be left in place to dry. A dilution of 7:1, H2O to Safety Foam has proved successful in the past.


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13. General limitations of cementitious floors Mineral Aggregates -

Where operating and service conditions dictate the use of a metallic aggregate surface hardener for greater abrasion and impact resistance.

-

For use in areas exposed to acids and their salts or to materials known to deteriorate cement concrete, consult your BASF Construction Chemicals representative.

Metallic Aggregates -

Where floor surfaces will be exposed to acids, salts or to materials known to deteriorate cement, consult your BASF Construction Chemicals representative.

-

Areas of constant high humidity from ambient or ground water (toilets, wash places, etc…)

-

On concrete that contains chlorides and/of saltwater.

14. ing Documents •

Floor Service Report (example copy on the next two pages).

•

Technical datasheet of all products mentioned are available in the launch pack.

•

Launch Presentations – see launch pack.

•

Cementitious Floor Problem Solving Guide – will be available shortly


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Cementitious Flooring / Dry Shake Floor Service Report Project: General Contractor: Applicator: BASF Representative: BASF Products Used & Lot #:

Location: Owner: Specifier: Date:

GENERAL

□ Under Roof □ Outdoor □ Suspended Sub-Base: □Soil □Rebar □None Slab-Reinforcement: □Mesh

□Gravel

□ Poly

Total size (m2):

WEATHER

□ Hot

□ Humid

□ Arid

Temperatures: Ambient (Placement Area):

□Cold □Windy

□ Snow

Concrete:

□ Rain

Sub-Base:

CONCRETE ixtures:

Designed MPa:

Dosage:

Slump:

Air%:

□ Calcium Chloride □ Water added at job site

Supplier:

l/m3

PLACEMENT

□ Strip Pour Straightedge: □ Wood

□ Checkerboard □ Metal

□ Wet Screed Placement begun: □ Power □ Vibratory □ MASTERKURE 111CF

CREW # of Finishers:

Cooperation: □ Good

# of Labourers:

□ Fair □ Poor

LEVELLING/FLOATING

□ Wood Bull Float Combination Blades

□ Mag. Bull Float □ Float Shoes # of Float Machines: □ Wood Hand Floats □ Mag. Hand Floats


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□


APPLICATION Spec. kg/m2:

□ Iron Armoured ts □ Bleed Water □ Bleed Water Removed

kg/m2 Used:

□ Bags counted and placed □ Masterkure 111 CF used □ Slap floated prior to shake ___ (time) □ Machine □ Hand Depth of foot impression: _____ □ 1st shake: (time) □ 2nd shake: (time) □ Final Trowel: (time) APPLICATION: □ Behind bull float □ By hand □ Other: ________ # of Bags applied: □ Water added to Dry Shake TROWELING

□ Flat Trowel 1st FINAL TROWEL □ Hand □ Machine FINISH □ Non-Slip □ Smooth □ Blisters □ Water sprinkled on surface # of Trowel Machines: □ Gassed □ Working □ Unreliable Condition of Finishing Equipment: □ Clean CURING Moist cure:

CURING METHOD:

□ Curing Compound (brand name) □ Finished floors protected from weather and other trades

Coverage

hrs m2/l

TS Time before sawing: Distance between sawed ts

□ Flushed Clean □ Tape Applied

□ Good □ Fair □ Poor m Construction ts m □ Doweled □ Tooled ts □ Other ts (type) Appearance

Comments

(BASF representative)

Signed:


Page 50


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