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Industrial High Tolerance
Floors
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High Tolerance
Concrete Floor Slab Stages of Construction
Stage (1)
The water proofing slip membrane is placed after level checking of sub-base and
then the form construction is placed according to design and leveling
accurately. The concrete is then placed in the slab straight from the ready
mixed concrete truck.
Stage (2) Compaction & Levelling of Concrete
Fresh concrete is bring to accurate level & compacted by means of a special
aluminum straight edge with a special section that is not allowed to bend under
concrete load. Large bays till 12.00m wide could also be laid mechanically with
less accuracy sufficient for production areas decreasing no. of joints.
Stage (3) Finishing Operation
A power-trowled floor finish is obtained in two stages:
(a) Power-Floating the stiffened concrete to even cut any slight irregularities
left from the aluminum straight edge. The power-Float is a power machine
driving a rotating circular steel disc. The power-Float must be used for the
initial power floating operation only.
(b) Final power troweling to close the surface, making it smooth & dense.
This is done by a power trowel supplied by different kinds of blades with
changing tilting angles mainly depending on the stage of setting &
stiffness of concrete.
N.B.
1. If a dry shake surface hardener is required to be used, a first shake of the
material is spread (2/3 the required consumption) before the power floating and
the remaining of the consumption is spread before the first power trawling. It
is to be noticed that our system - In spite of being adapted to use dry shake
material- does not need a high consumption of the a/m hardener as our finishing
techniques can achieve this hardness of the floor surface.
2. If it is required to apply Epoxy Mortar, the floor surface will be left is a
stage, a little bit before the final finishing to get a " broom
finish" required for Epoxy Application.
3. For Epoxy Paints & self-leveling coating, finishing is achieved to the
final stage as discussed before.
4. In all floors that will be covered with Epoxy, it is essential to place a
vapor-barrier before application.
Stage (4) CURING
Concrete floor surfaces must be continuously cured for at least 7 days.Wet
curing of the concrete surface is done by fully covering the floor with
impermeable plastic sheeting as soon as it can be placed without marking the
surface for 7 days and then after this wetting is continued for 14 days. Curing
will prevent the concrete from rapidly shrinking out and will allow it to gain
its full compressive strength. Good curing will reduce the risk of cracking,
crazing and dusting.
Also a curing compound can be painted on the surface just after finishing ends
achieving the same benefit and preventing the hydration water of cement form
going out.
Stage (5) STRESS-RELEASE JOINT
Within 72 hours form concrete surface being finished, stress-release joints are
constructed by saw-cutting with a max. width of 3-5mm. The depth of the cutting
is according to the slab thickness.These joints are to be filled later on by an
appropriate joint sealant (usually after 28 days from last by casting).
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