1. Cement-Based Flooring Systems The Good, Bad and the Ugly H. Peter Golter, PE

2. 2 Presentation Agenda Brief Overview of Concrete Brief Overview of Floor Rehabilitation/Resurfacing Project Overview – Moisture Related Problems Project Overview – Fast Track Construction Project Overview – Structural Deficiency/Floors Out-of-spec Recap – Review Successful Finish Floor Installations

3. Brief Overview of Concrete Indestructible, Right? How many types of concrete are there? What are they? 3

4. 4 What are Floor Resurfacers? * Referencing ACI 116R-00 Cement and Concrete Terminology Toppings* A layer of concrete or mortar placed to form a traffic bearing floor surface on a concrete base Underlayments A thin capping of existing concrete, wood or primed metal floors to provide a surface suitable to receive floor covering or coating

5. 5 What are Floor Resurfacers? A thin build of material used to cover and level defects in concrete, vinyl, tile, metal, wood and other subfloors To strike off a trowel grade, cementitious material to fill in or level rough concrete surfaces prior to the installation of floor coverings ScreedsSkim Coats

6. 6 Why are Floor Resurfacers Necessary? Requirements for concrete contractors To correct or modify existing jobsite conditions Requirements for flooring manufacturers +/- 1/4” in 10 lineal feet+/- 1/16” in 10 lineal feet There are different industry standards for the different trades Example:

7. 7 Advantages of Floor Resurfacers With floor resurfacing products, installers can meet any flooring system requirement The following floor finishes require smooth floors –Vinyl sheet goods –Wood –Thin coatings –Stains –Sealers Units of measurement: –+/- “x" inches/10 feet –Flatness (Ff) –Levelness (Fl) Level a floor within required specification Wood flooring Self-leveling underlayment Adhesive Concrete substrate Primer/admixture (when required) Patching material

8. 8 Commercial Applications Offices Educational facilities Municipalities

9. 9 Residential Applications High rises/condominiums Single-family homes Townhomes

10. 10 Healthcare Applications Medical office buildings Outpatient facilities Assisted living facilities Hospitals

11. 11 Retail Applications Restaurants Malls/shopping centers Big box and shoe box

12. 12 Industrial Applications Food processing Chemical Pulp and paper Manufacturing Warehouse

13. 13 What Technologies are Available Today?

14. 14 Available Technologies Gypsum: least expensive, most common material Portland-based: moderately priced; wide range of applications Modified Portland: –Polymer: Adds density and flexural capabilities –Pozzolans: Densifiers and increases ultimate strength Self-drying cements: Extremely quick return to service due to rapid internal hydration Polymers (resins): Very expensive, engineered plastics; typically vapor barriers Price High Low Performance Low High Gypsum Portland- based Modified Portland – pozzolans Modified Portland – polymer Self-drying cements Polymers (resins)

15. 15 Advantages of Floor Resurfacers A variety of products are engineered for longevity and durability for the following traffic conditions: –Residential foot traffic –Commercial foot traffic –Vehicular traffic –Industrial hard wheel traffic –Steel wheel traffic Support the traffic load NOTE: Contact the manufacturer for specific material or product recommendations

16. 16 Advantages of Floor Resurfacers Conventional concrete is 3,000- 4,000 psi compressive strength Engineered materials with performances up to and exceeding 10,000 psi for greater longevity and reduced maintenance costs Abrasion resistance

17. 17 Who is Typically Involved in These Projects? What does a winning team look like? OwnerArchitectEngineer Contractor/ Specialty Contractor ManufacturerSupplier

18. 18 What is the #1 Priority for Any Property Owner? VALUE!

19. 19 Perception versus Reality Factory-fabricated samples for system selection Insist on representative jobsite mockups Use jobsite mockups and field flow tests as quality assurance

20. 20 What Happens with Moisture in the Concrete?

21. Concrete and Moisture Every flooring manufacturer has specific requirements regarding the moisture content of concrete to receive their flooring. These requirements must be made known to the specifier, architect, general contractor and flooring specialist. Setting and Meeting Expectations

22.  Don’t install until it passes  Wait for the concrete to dry  Accept a sign off from the general contractor!? When Moisture Testing Fails…

23. Modes of Concrete Floor Moisture Failures  Adhesive breakdown  Disbonding  Alkali attack  Microbiological activity  Staining  Efflorescence  Condensation  Curling

24. Adhesive Breakdown

25. Disbonding

26. Adhesive Oozing

27. Mold

28. Efflorescence

29. Moisture in New Concrete New meaning to embedded steel

30. 30 How Fast is – Fast Track Construction?

31. Fast Track Construction Rehab a Floor Over the Weekend 31

32. Preparing the Floor 32

33. Application of Primer Existing Concrete and Epoxy Coating 33 1-Comp. Primer

34. Attention to Details Weigh out the Pigments by Batch 34

35. Delivery Method 35

36. Gauge Rake – Proper Depth Smoother – Get the “Glass” Finish 36

37. Protect the surrounding area Final Clean-up Integral Color & Sealed – Before and After 37

38. Finished Floor 38

39. 39 Structural Deficiency – Floors Out of Spec

40. What Went Wrong? Structure was “Value Engineered” Construction was awarded to “Low Bidder” Bonus to GC to complete the project early Project Schedule was compressed Does “Pisa” come to mind? 40

41. What Is The Solution? Analysis indicates dead loads are a major consideration. Design Criteria: –Level the floors. Some areas 3+ inches –Maximum 60#/Cubic Foot for repair material –Material must be at least 3,500 psi for finish flooring manufacturer’s to warrant their product –Quick return to service, next day trades are on it 41

42. Repair Material Staged on Job 42

43. All floors marked to finish elevation 43

44. All floors marked to finish elevation 44

45. Surface Preparation - Shotblasting 45

46. Application of Primer 46

47. Verifying the Finish Elevation 47

48. Water Source and Pump 48

49. Getting Ready to Pump 49

50. Pump Operator 50

51. Mixed Material Going into Pump 51

52. Material being placed and finished 52

53. Floor is now level!!! 53

54. Finished Cured Floor 54

55. What is the Size of the Project? 55

56. Bldg#2 - So what went wrong? 56

57. 57 Finished Installations

58. 58 Finished Installations Gone Wrong Wavy floors (i.e., sheet goods, epoxy coatings) Hollow spots under wood floors Transitions to different finished flooring materials (i.e., carpet, wood, sheet goods and tile)

59. Cement Masons A Wear Topping Stained and Polished 59

60. LA Restaurant Stained and Polished 60

61. 61 Finished Installations Done Correctly Screeds Self levelers What is the primary function? –Utility (warehouse floors) –Decorative (commercial floors) Toppings

62. Finished Floors 62

63. 63 Finished Installations Done Correctly Large body tile or stone placed tight together Slope to drain ADA compliance Screeds (dry pack and wet mix)

64. 64 Examples of Finished Installations Installation consisting of −Screed floor (mud bed) −Polymer modified thin set −Porcelain body tile −Polymer modified grout

65. 65 Examples of Finished Installations Installation consisting of −Skim coat −Carpet adhesive −Carpet tiles

66. 66 Examples of Finished Installations Installation consisting of −Self-leveling underlayment −Urethane wood adhesive −Pre-finished engineered wood

67. 67 Examples of Finished Installations Installation consisting of −Self-leveling underlayment −Mastic −VCT

68. 68 THANK YOU FOR YOUR TIME! QUESTIONS? www.prospec.com 800.334.0784