Seamless (self-leveling) floors made of polymer materials. Seamless floor coverings, types, design schemes and device defects Thin-layer polymer coatings

Seamless floors are a monolithic coating consisting of a synthetic binder, cement and fillers. To increase durability and strength, floors are made of several layers, which are structural elements floor.

Based on the nature of the structure, seamless floors are divided into floors on the ground and floors on slabs.

For the construction of seamless floor coverings, polyvinyl acetate and polymer cement compositions are used, as well as polymer concrete compositions based on epoxy, polyester and phenol-formaldehyde polymers.

The use of compositions makes it possible to obtain coatings of high static and dynamic strength, wear resistance, density, and chemical resistance.

The simplicity of the technology for manufacturing the compositions, as well as the high industrial level of construction of the floor itself, makes it possible to consider seamless floors the most advantageous compared to others.

The technology for preparing compositions for seamless coatings includes: selection of composition, dosing, mixing to a given consistency (mobility, hardness).

Seamless floor coverings must meet the following requirements: the surface of the coating must be smooth, without noticeable seams and joints, roughness, sagging, cavities, and dirt; the color of the coating must be uniform over the entire floor area and the thickness of the front layer; the coating should not peel off from the base, crack or peel when the compositions harden and the floor is used.

Polyvinyl acetate coatings. Floors made from compositions prepared on the basis of polyvinyl acetate dispersion are quite strong and wear-resistant, beautiful and hygienic, do not require large labor costs and are very economical due to the low cost of raw materials and simple construction technology.

The composition of such a coating includes: polyvinylacetate dispersion, ground quartz sands of light-resistant pigment, water.

Poly vinyl acetate dispersion (GOST 18992-80*) is a product of polymerization of vinyl acetate in aquatic environment in the presence of an initiator and a protective colloid. When covering the floor, the following brands of polyvinyl acetate dispersion are used.

Synthetic latex SKS-65GP (GOST 10564-75*) is obtained by joint polymerization of butadiene with styrene in a ratio of 35:65 by weight in water

Fillers are added to reduce the consumption of binders and regulate the physical and mechanical properties of finished products.

The most common filler is quartz ground sand (GOST 9077-82) with a specific surface of 200 m2/kg and bulk density of 1200-1500 kg/m3.

Residue on sieve N 005 is no more than 20%, humidity is no more than 2%.

Plasticizers serve to lower the glass transition temperature of the polymer and increase its elasticity. For aqueous polymer dispersions, dibutyl phthalate DBP and dioctyl phthalate DOP are used. The density is respectively 1050 and 980 kg/m3, transparent oily liquids.

Depending on the ratio of polymer and filler, mastic polyvinyl acetate compositions are classified into elastic coatings (1:1), hard coatings (1:2) and slag coatings (1:4) (Tables 55, 56).

Polyvinyl acetate mastics are prepared under construction conditions using turbulent mortar and concrete mixers. After dosing, the components are loaded in the following sequence. Pour in water and load the dispersion, mix for 10-15 s, add pigments and mix again for 10-15 s. Then load the filler and mix until a homogeneous mass is obtained. The mastic must be used within 5 hours.

For the installation of seamless floors, factory-made compositions are used (Table 57), which require the introduction of only a hardener at the work site.

Sequence of work on installing a polyvinyl acetate coating (Fig. 57): thorough cleaning and dust removal of the room; leveling the base; grinding the screed or base; surface priming; application of a monolithic seamless composition; coating finishing.

Leveling and facial coatings are applied in two layers 1-1.2 mm thick. Each subsequent layer of mastic is applied only after the previous one has hardened. The color of the front layer must match the color of the layer below.

Rice. 57. Solid floors based on aqueous polymer dispersions
a – on a concrete underlying layer along a screed; b -on the stove floors on screed; c - on the floor slab; d - on the floor slab over a screed laid over a heat- or sound-proofing layer; 1 – coating; 2 - screed; 3 – heat or sound insulating layer; 4 - floor slab with a flat surface; 5 - floor slab with uneven surface; b - foundation soil; 7 – concrete underlying layer

Rice. 58. Xylolite and polyvinyl acetate-cement-sawdust floors
I - single-layer; II – two-layer; a- on the ground; b - on the floor slab; c - on the floor slab over a screed laid over a heat- or sound-proofing layer; 1 – single-layer coating; 2 - two-layer coating; 3 – screed; 4 - heat or sound insulating layer; 5 - floor slab; 6 – foundation soil; 7 - concrete underlying layer

The mastic begins to be applied from the wall opposite the entrance doors.

During the application of mastic, the thickness of the applied layer is systematically checked with a gauge. In order to increase performance qualities and improvements appearance coating, two to three days after applying the mastic, it is coated with pentaphthalic varnish PF-211 or a mixture of pentaphthalic varnish PF-170 with oil-resin varnish in a ratio of 3:2 (twice).

Polymer cement coating. Depending on the consistency of the polymer composition and the coating manufacturing technology, there are three main types of polymer-cement coatings (Fig. 58): mastic, made by spraying from special spray nozzles or by bottling; mortar, produced by bottling and used as a solution for the use of ceramic tiles; concrete, the installation of which is carried out by laying machines.

Polymer-cement compositions are characterized by high strength, water resistance, wear resistance, frost resistance and resistance to aggressive environments.

When constructing polymer-cement coatings, the following materials are used: Portland cement grade no lower than 400, divinyl styrene, SKS-65 latex, construction sand, marble or granite chips, stone flour.

The P/C ratio is usually used 0.15-0.2. Fine-grained sand (less than 0.63 mm), ground sand and stone flour are used as aggregates.

Alkali-resistant mineral pigments are used to color the compositions.

Water is introduced into polymer-cement compositions in a minimal amount to obtain a rigid but easy-to-lay mixture. Excessive amount of water leads to a decrease in the strength of the composition and cracking of the coating. To accelerate the hardening of the compositions, calcium chloride or a stabilizer solution is introduced into them. To increase the water resistance of the compositions, ammonium dichromate is added.

Depending on the purpose, finishing and preparatory polymer-cement compositions are distinguished.

The former are used for installing a front covering, the latter for installing a screed and complete or partial leveling of the surface.

The components of polymer cement compositions are mixed for 8-10 minutes, and ready mix must be laid within 2 hours. The thickness of the coating is recommended 20 mm.

Coverings are installed over an underlying layer or concrete screed, or over reinforced concrete floor slabs.

Laying the mixture begins from the wall opposite the entrance and is carried out in sections (strips) 2.5-4 m wide, limited by guide rails and beacons. The mixture in the strip is distributed and developed according to the rule. The surface is smoothed with metal trowels.

After acquiring strength, the surface should be sanded after three days. Grinding is carried out using the wet method, moistening the surface and sprinkling with coarse sand, which serves as a free abrasive and speeds up grinding. The work is carried out in two stages - first with coarse-grained abrasives, and then with fine-grained ones, until a clean and smooth surface is obtained. When the concrete reaches a moisture content of 4-6%, the coating is coated with varnish UR-293, UR-294.

Polymer concrete coatings are used for flooring in rooms with heavy traffic of people and vehicles on rubber tires. Aqueous polymer dispersions are used as a polymer binder (usually PVA dispersion or SKS-65 latex) (Fig. 59).

Ground quartz sand (GOST 9077-82) is used as a fine aggregate, and crushed marble and granite with a particle size of 5-10 mm are used as a coarse aggregate.

Rice. 59. Floors with seamless coating based on thermosetting resins
I - with a single layer coating; II – with a reinforced layer; III with elastic and reinforced layers; a “on the ground; b - on the floor slab; c - on the floor slab over a heat or sound insulating layer; 1 - coating; 2 - screed; 3 ~ floor slab; 4 - heat or sound insulating layer; 5 - foundation soil; 6 – underlying layer; 7 - reinforced layer; 8" elastic layer

Recommended polymer composition concrete coverings next, by weight: cement M400-1; water - 0.25; crushed stone - 2.6; sand - 1.4; polyvinyl acetate dispersion - 0.3; pigments - 0.05-0.1. The mobility of the concrete mixture is 3-4 cm.

Properties of such polymer concretes: abrasion no more than 0.8 g/cm2, water absorption no more than 2%, softening coefficient 0.6-0.7 (for concrete with PVA dispersion) and 0.8-0.9 (for SKS-65 latex ), compressive strength - 25-30 MPa.

Mineral light-resistant segments are used to impart color to the coating.

Polymer concrete coatings are laid on a cement screed, which is pre-cleaned and primed with a polyvinyl acetate emulsion with water of a 1:1 composition.

The concrete mixture is prepared in concrete mixers. First, pour the polymer cement dispersion and water and fill required amount dry pigments, mix 3-4 mm and add cement. After two to three minutes of further mixing, the aggregates are introduced. Total time stirring for 8-10 minutes.

The concrete mixture is supplied to the prepared base in strips between the lighthouse gratings and leveled. Laying the mixture starts from the wall opposite the entrance. The surface of the laid mixture should be 5 mm higher than the lighthouse slats. The laid mixture is compacted and smoothed.

To increase the wear resistance of concrete coatings, various methods of processing concrete surfaces are used: grinding the floor surface; sprinkling the freshly laid concrete surface with powders from solid materials; treating the concrete surface with sealing compounds, of which the following methods are most applicable:
a) silicification with soluble glass,
b) fluting,
c) hydrophobization; applying wear-resistant film coatings based on polymer materials (polyurethane, epoxy, polyester and other resins) to the surface of concrete.

The most common method is to coat the surface with special compounds.

Xylolite coatings. Xylolite is intended for flooring in residential, public and industrial buildings, in which there is no constant moistening of the floor and exposure to aggressive media (acid, sugar, etc.) that destroy xylolite. Xylolite floors are hygienic, durable, warm, and fire-resistant.

Xylolite is made on the basis of sawdust, which acts as a reinforcing substance and xylolite mixture, caustic magnesite, used as a binder, and magnesium chloride. It is used in the form of a solution or slabs.

Xylolite floors are made on wooden, concrete and cement-sand screeds. Their strength must be at least 7.5 MPa, humidity no more than 5%, thickness 20-40 mm.

The surface of the freshly laid layer is cut with grooves for better adhesion to the xylolite coating.

The process of laying xylolite floors is carried out after all work related to humidity processes has been completed in the room, at a temperature not lower than 10 ° C.

To prepare the xylolite mixture, magnesite, pigment, and sand are thoroughly mixed, then sawdust is added and sealed with a solution of magnesium chloride. The mixture should have a mobility corresponding to the immersion of a standard cone of 2-2.5 cm.

Before laying xylolite coatings on it, the concrete surface is primed with a mixture of a solution of magnesium chloride and caustic magnesite (mixture composition 4:1 by weight).

The xylolite mixture is laid in one layer of the thickness specified in the project, and is carried out in strips 1.5-2 m wide. The xylolite mixture is leveled using a rule and compacted with tampers. If, when compacting, a lot of liquid comes out on the xylolite coating, its surface is sprinkled with a dry xylolite mixture. The surface after compaction is smoothed with trowels. Smoothing should be completed before the xylolite mixture begins to set.

To increase the service life of floors, after hardening they are sanded (rough and final) and impregnated with varnish, as well as polyvinyl butated primer VL-278. Floors can be polished with mastic. Composition of mastic in parts by weight: paraffin-2; ski-pedar-1; kerosene-5.

In industrial buildings, xylolite floors are periodically wiped with sawdust soaked in mineral oil. Once a month, wash it with water and, after drying, lubricate it with mineral oil.

Metal structures and parts in contact with the xylolite coating are protected from the action of magnesium chloride.

Mosaic (terraz) coverings. Mosaic coverings are installed mainly in public buildings, lobbies, end halls, etc.

This type of coating refers to monolithic floors and has a number of positive qualities: hygiene, moisture resistance, durability.

The mosaic coating consists of a cement-sand layer 20 mm thick and a mosaic mortar coating 20-25 mm thick.

The main technological operations are preparation of the subfloor, installation of veins, preparation of mosaic mortar, installation of coatings, grinding and polishing of mosaic coatings.

Mosaic coverings are generally installed over a concrete underlying layer. To prepare a mosaic mortar, a pre-mixer is loaded into the mortar mixer.

Rice. 60. Terrace floor
1 - concrete preparation; 2 - sand 6 mm; 3 – cement preparation; 4 - layer cement mortar; 5 – glass slats; 6 - terrazzo different colors

thoroughly mix cement with pigments and crumbs of appropriate sizes, add the required amount of water and mix for five minutes. The mobility of the mosaic mortar during installation is no more than 2-4 cm. The grade of the mortar is not lower than 20 MPa (Fig. 60).

The separating veins are made of glass 3-5 mm thick, brass or polymer materials. The top of the veins is carefully verified and placed at the level of the clean floor. The installed veins are secured with a mosaic mixture or cement-sand mortar.

As the veins are arranged, the mosaic mixture is laid, leveled and compacted along the veins, which are used as lighthouse slats.

Sprinkling concrete and mosaic coverings with cement when smoothing them is not allowed. During the hardening period, the mosaic coating must be protected from rapid drying.

After three to six days after laying the mosaic covering, when its strength eliminates the possibility of chipping marble chips, proceed to finishing, grinding and polishing.

Rubbing consists of processing the mosaic covering abrasive materials in order to remove the layer of solution.

Grinding - surface treatment with fine-grained abrasive materials.

The surface to be scrubbed is moistened with water and sprinkled with quartz sand. Skirting boards are installed before polishing.

Before putting the mosaic floor into operation, the coating is rubbed with mastic.

Defects in seamless coatings.

1. Seamless coatings sometimes collapse earlier deadline(coating peeling, cracks appearing) - aggregates of insufficient strength or containing a large number of dust particles; concrete mixture had great mobility; incorrectly recommended water-cement ratio; the thickness of the coating was not chosen enough, which caused local destruction; the adhesion of the coating to the underlying layer was disrupted, which caused a sharp decrease in the strength of the concrete coating.

2. The appearance of efflorescence - the presence of salt impurities in the solution or preparatory layer.

3. Spotting is a consequence of incorrect dosage and insufficient mixing of the solution.

4. Variation in mosaic coating - careless dosage and mixing of the dry mixture.

Seamless floor covering- the upper element of the floor, which is a continuous layer or divided into cards by special veins, formed during curing building mixtures. Seamless floor covering is subject to operational influences. By its name the name of the entire gender is established.

Seamless floors are hygienic, characterized by easy surface cleaning, high abrasion resistance, heat and chemical resistance, frost resistance, resistance to impacts and scratches. The technology for their manufacture is quite simple. They are characterized by high decorativeness. But installing such floors is more labor-intensive than installing floors made from roll materials.

Requirements for materials for seamless floors: no peeling from the base after application to the floor, no cracking during hardening and during operation.

Depending on the type of polymer raw material used, seamless floors are distinguished: polyvinyl acetate, polyester, polyurethane, epoxy, etc.

By constructive solution and methods of execution, seamless floor coverings are divided into:

Mastic - made from cast compositions based on a binder with a small amount of filler by spraying or pouring, followed by leveling. Their common feature- small thickness (up to 5 mm);

Mortar - characterized by the presence of filler with a particle size of up to 7 mm and a thickness of 5-20 mm;

Concrete - containing aggregate larger than 7 mm, with a thickness of 20 mm or more.

Seamless floor coverings are made monolithic based on aqueous dispersions of polymers or reactive oligomers.

Floor coverings based on aqueous polymer dispersions - continuous layers of polymer binder (most often polyvinyl acetate dispersion or styrene-butadiene latex) and filler (finely ground stone material of light colors - marshalite, ground quartz sand, etc.) with a particle size of no more than 0.15 mm. To color the compositions, light-resistant mineral pigments are used: redoxide, chromium oxide, red lead, etc. Modifying additives (polystyrene latex, aqueous rubber dispersion, resorcinol-formaldehyde resin) and stabilizers can be introduced.

Coatings are dust-free, conditionally electrically conductive(electrical resistance value from 104-106 Ohm-cm), do not accumulate charges of static electricity on their surface, are classified as sparking, easily cleaned from dust-like and moderately cleaned from liquid industrial contaminants.

The coating based on aqueous polymer dispersions consists of a leveling layer and a top layer. In leveling compositions, quartz sand with a particle size of 0.2-0.3 mm is used.

Coverings are installed over a cement or gypsum based screed and over a floor slab with a flat surface by spraying using compressed air or airless spray installations. They are used in rooms with heavy pedestrian traffic, in administrative offices, design offices, auditoriums, for which increased requirements for cleanliness are imposed. They cannot be used in areas with heavy traffic on rubber tires.

Floor coverings based on reactive oligomers are continuous layers of cold-curing polymer resins, mineral fillers and pigments. Binder - epoxy, polyester, polyurethane resins.

Fillers - finely ground powders: mineral (andesite, quartz, borate ore, etc.) and polymer (polyethylene, vinyl plastic). Filler - quartz sand and porous glass-crystalline crushed stone of fraction 1.5-10 mm. Mineral and organic dyes are used as pigments. Additives are added to the mastic to improve flow, impart fire resistance, stabilize and improve adhesion. Self-leveling epoxy mastic coatings

They are dust-free, non-conductive (electrical resistance value is more than 106 Ohm-cm), accumulate charges of static electricity on their surface, are classified as sparking, and can be easily cleaned from dusty and liquid industrial contaminants.

The design of monolithic coatings includes a primer layer of varnishes that do not contain filler, a base layer and a finishing layer.

Finishing layers can consist of a layer of colored low-filled polymer solution on a base layer binder, 2-3 layers of wear-resistant varnish (mainly polyurethane); layer of chips - flat chips 10-15 mm long and wide and 0.7-1 mm thick made of colored plexiglass (polymethyl methacrylate) or vinyl plastic (polyvinyl chloride), slightly embedded in the unhardened base layer and covered with 1-2 layers of polyurethane or epoxy colorless transparent varnish ; a decorative layer formed by embedding marble chips into a binder followed by grinding the surface. The coating may contain additional layers. To increase the crack resistance of the coating, it is advisable to introduce an elastic layer made of compounds that have an elastic modulus several times lower compared to the coating material (epoxy-rubber mastics, thiokol sealant and some sheet materials

Depending on the type of filler, degree of filling and technology for applying the base layer, seamless coatings are divided into self-leveling, highly filled, and frame.

Self-leveling coatings are made from a binder composition with fine filler taken in a ratio of 1:1.5 by weight. A layer 1.5-3 mm thick is applied by pouring, followed by leveling.

Highly filled coatings are made from a composition of resin and sand in a ratio of 1:6. It is applied using trowels and trowels.

Layer thickness - 5-9 mm.

In frame coatings, a porous frame is initially made of crushed stone, then it is impregnated with an unfilled polymer composition.

Layer thickness - 15 mm. Polyvinyl acetate and latex mastic coatings Polyvinyl acetate mastic coatings are made from a mixture of plasticized polyvinyl acetate dispersion, mineral powder, pigment and water. Mastic composition (by weight): polyvinyl acetate dispersion - 1; mineral powder - 0.8-1.5; pigment - 0.15-0.25; water - 0.3-0.5. Recommended use latex mastic

industrial production

(TU 21-29-141-88), which is a mixture of an aqueous dispersion of SKS-65TP latex, stabilizer, filler, pigment and modifier. Finely ground stone materials (marshallite, quartz sand, marble, etc.) with a compressive strength of at least 60 MPa and a particle size of no more than 0.15 mm should be used as mineral powder. The powder should not contain lumps, clay, organic and other impurities and humidity more than 5%. Pigments should be finely ground, loose, without lumps. Before use, they should be ground with a little added water.

Preparation

polyvinyl acetate mastic composition

: Polyvinyl acetate dispersion is mixed with water and powder, and then with pigment. The finished mastic should be strained through a sieve with 0.6 mm mesh. Foam that floats to the surface of the mastic after 15-20 minutes of settling must be removed., made on the basis of polymer materials, are the most hygienic and convenient to use, and have high abrasion resistance.

Compositions for creating seamless floors are made on the basis of polymers, fillers and cement (for polymer-cement compositions). Depending on the raw materials, seamless floors are divided into three types: polyvinyl acetate, polymer cement and polymer concrete. The consistency of the compositions can be plastic, which are laid using laying machines or vibrating devices, and bulk, which are applied by spraying or pouring; by purpose - for the front layer, screed and putty layer. The compositions of all types of monolithic floors must ensure the possibility of obtaining a smooth surface without joints, sagging, cavities or roughness over the entire area, with a uniform color. The coating should not peel off from the base, crack or peel during use.

Seamless floor coverings made from polyvinyl acetate mastics and polymer-cement compositions are used for residential, public and industrial buildings and structures. Polyvinyl acetate compositions are not used in rooms with high humidity, as well as in industrial buildings with possible shock loads or heavy-duty transport. In construction practice, polyvinyl acetate mastics and polymer-cement compositions are most used.

Seamless floors made from polyvinyl acetate mastic can be made in one or two layers. A single-layer self-leveling coating is placed on a well-prepared flat surface thickness 1.5...2 mm. Depending on the intensity of traffic and operating conditions of the floor, the thickness of the facing layer can be increased to 4 mm. If the condition of the base is unsatisfactory, two-layer coatings with a thickness of 3...4 mm are used.

On modern market building materials roll materials are represented by various types of pile coverings and linoleums. These types of coatings are widely used in office, residential and other similar premises with low traffic volumes.

Linoleums (Latin linum - canvas, oleut - oil) originated in England in the middle of the 19th century. Then linoleum was obtained by applying a highly filled paste of cork flour and natural drying oils to a fabric base. This was the so-called natural linoleum, which was replaced by polyvinyl chloride (PVC)-based linoleum by the mid-20th century.

Currently in Western Europe they began to produce linoleum using natural raw materials again. This material can be found in small quantities on our construction market. Bulk linoleum various types made on the basis of plasticized PVC.

Linoleums are produced in a wide range of colors with a variety of patterns, both without a base and on a base (including heat and sound insulation). Linoleum on a heat and sound insulating base can be laid directly on the screed without installing intermediate layers. Linoleum panels have a width of up to 4 m. The wider the linoleum panel, the less likely it is that the seam formed when individual panels meet will end up “in the most visible place” in your room.

Linoleum provides an elastic, quite beautiful and easy-to-maintain floor covering, but requires a smooth, even and solid foundation. You cannot use ordinary linoleum in rooms with high traffic intensity; in this case, rapid wear and loss of the appearance of the coating occurs, which is wrongfully attributed to the low quality of the linoleum itself.

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As is known, concrete screed until recently it remained the most popular when organizing floor coverings. If necessary, it was decorated ceramic tiles or other materials. But they no longer meet the requirements for floor coverings due to their shortcomings. In turn, self-leveling seamless flooring is free from almost all disadvantages. In addition, when correct selection coatings reveals all its positive traits. This coating is laid in an even layer without seams or technological holes, forming a hard, smooth surface, which, depending on the choice of polymers, has additional qualities. By the way, you can order from us by calling or writing a letter.

Composition of self-leveling floors

Seamless floor: types and classification

Based on the polymer components used, seamless floors are divided into four main groups with their own properties. Therefore, before installation, you should familiarize yourself with their features and use the most effective composition.

The self-leveling floor is laid in a perfectly even layer without seams, technological holes and other defects

• self-leveling floors based on epoxy components have excellent adhesion to the concrete base, high strength and wear resistance. This allows the use of heavy equipment indoors;
• self-leveling acrylic floors, which are based on methyl methacrylate, do not interact with most acids and alkalis. In addition, they are inert to fuels and oils, therefore they are widely used in production workshops chemical plants, garages and service stations. The absence of seams prevents the absorption of aggressive media during spills and promotes their rapid neutralization;
• polyurethane self-leveling floors Along with high strength, they also retain some ductility. Widely used in industries with complex and heavy technological equipment, transmitting vibration to the floor covering;
• self-leveling polyester coatings- This is an environmentally neutral composition. When it hardens, a dust-free and durable coating is formed that successfully resists impact loads and compressive forces.

Self-leveling floors have an interesting structure due to the presence of quartz sand of various fractions and colors. The seamless structure of the floor is best demonstrated after sanding and treatment with polymer varnishes.