INNOVATIVE FLOORING

From the Stone Age era the flooring is an important part of any civil engineering structure. Initially flooring was made by earth or cow dung, then came the stone flooring, then concrete floor of lime concrete or cement concrete, then came the new age flooring. The new age flooring is been developed on the basis of its requirement. The flooring of any structure needs very special care in its designing, executing & finishing. As the flooring is suppose to be acts as a barrier to the many types of effect such as weathering, water penetration, abrasion. The flooring systems can be classified in two ways 1) Residential Flooring 2) Industrial Flooring.

For both type of floorings each flooring is to be designed, executed & finished as per their requirement.

1) RESIDENTIAL FLOORING :

The flooring of any residential complex are either made up of concrete or stone. In residential flooring system, the flooring in structure is provided for following purposes:

a)     For aesthetic purposes

b)     For prevention of water penetration under base.

c)     For prevention of entry of termites to the home.

Broadly the flooring of any residential can be classified as follows.

A)    Concrete floors

B)    Stone floors 

A)    Concrete Floors:

In residential quarter concrete floors should be laid in 30 to 50mm thick layers over 80 to 100 mm thickness Base. Depending upon the requirement the concrete floor can be broadly classified as:

a)     IPS Flooring

b)     RCC Flooring

a)     IPS Flooring :

Where on flooring subjected load is not more the flooring should be laid as per requirement of IPS. IPS is an “Indian Polished Stone” or “Indian Pattern Stone”. The base for IPS should be made very well compacted. The compaction of filled up base can be achieved by means of mechanical compaction. Over compacted base, lean base of either brick bat or sand should be laid. Over it a 75mm thick layer of plain cement concrete or plain lime concrete is to be laid. Now a layer of 100 mm thick reinforced cement concrete is to be laid. The concrete should be laid in two layer of 50 mm each. Each layer should be compacted, vibrated to achieve dense & monolithic concrete. The minimum cement concrete content for the concrete should not be less than 300 kg/m³.  The final finishing of the IPS should be made with neat cement slurry, which is to be floated and finished perfectly to have a smooth finish.

b)     RCC Flooring :

Cement Concrete Floors :

In residential quarters concrete floors may be laid in 30 to 50 mm thick layers according to the wear and load expected on the floor. The top cement concrete should be laid before the base concrete has completely set (within 7 days). The surface of the base concrete must be moistened before laying the cement concrete. The hardest procurable aggregate should be used well graded from 20 mm down 1:2:4 mix., the matrix being 1 part of cement to 2.5 parts of aggregate, sand being added as necessary to make a workable mix, Minimum amount of water should be used so that no scum is formed on the surface when the concrete is beaten; the mix should have a slump of not more than 40 mm. Solid floors may be laid with 1:2:5 of medium aggregate.

The cement concrete, which should not be too dry, should be spread evenly immediately after it has been mixed, using straight edge; it should be at once well

Beaten and consolidated with 2.5 kg wooden rammers. The concrete is to be beaten until the mortar comes to the surface, which should be in less than 15 minutes; the floor should then be trowelled and finished.

Concrete floors under heavy Loads Or Those Exposed To Heat May Be Reinforced With Fabric (Light Reinforcement Of 150 X 150 mm mesh) placed 20 mm below the finished surface.

Granolithic finish is used to provide a hard wearing, abrasion resistant and dustless surface to concrete floors, and also where smooth polished and rich surface is wanted. Granolithic concrete is composed of cement and specially selected aggregate of hard rock and graded from 10 mm down to 150 micron (No.100 BS) sieve. Mix proportions are normally 1:2 or 1:3 by volume (all-in-grit aggregate); or may consist of 2 parts cement, one part of fine aggregate and 4 parts of coarse aggregate, coarse aggregate is graded form 10 mm or 6 mm down to 2.36 mm (No.7 BS) sieve and fine aggregate from 4.75 mm down. The all in aggregate specified above may consist of 3 parts of 10mm screenings and one part of 2.36 mm screening, with sufficient sand added to make a workable mix. Particular care should be taken to sift out all dust or fine material and to use minimum amount of mixing water, which will give adequate workability and will permit of satisfactory finishing. 

Best results are obtained where granolithic is laid before the base concrete has set. Many specifications require this to be done within 30 minutes after placing of base concrete, and in any case it should be done within two hours. The granolithic layer should be of 12 mm minimum thickness. The base concrete need not be smooth finished. The granolithic should be well tamped into place, screeded and lightly floated to required levels. Finishing, as described later, should be left for at least an hour after laying.

Where the base concrete has hardened, its surface should be roughened by hacking, laitance removed and well saturated with water and cleaned. Immediately before laying granolithic, any excess water should be removed and the surface of the concrete covered with a thin layer of neat cement grout well brushed in. The granolithic should then be laid as described above but in this case minimum thickness must be increased to at least 25mm and preferably 40 mm. An adequate key between the base concrete and the top finish is essential where the base concrete has set.

REPAIRING OF CONCRETE FLOOR :

Due to course of time, age deterioration flooring may get damaged and subsequently it requires repairing.

STONE FLOORING :

In residential complexes for asthetic purpose stone flooring is been provided. This type of flooring will provide tough durable flooring with good aesthetic out look. Following are the different kind of stone flooring.

Mozaic tile flooring

Kota stone flooring

Granite flooring

Ceramic tile flooring

Glazed tile flooring

Marble flooring

MOZAIC TILE FLOORING :

Where the asthetic purpose and loading parameter is not much higher mozaic tile flooring is preferred. In this system of flooring the flooring is to be laid over sound substrate. Firstly a sound layer of either RCC or PCC is to be laid up to thickness of 100 mm. Over the laid concrete a rich mortar of proportion 1:4 should be laid up to 50 mm thickness. The mortar should be admixed with integral waterproofing compound FAIRCRETE RMW. Over this layer selected mosaic tile should be laid in perfect required level. After 24 hours of fixing of tiles, the joints should be sealed with FIRFIX TG. As the whole system is cement based it needs full submerged curing for 7 days.

Kota/Granite/Marble Flooring :

Where the asthetic and durability requirement of the flooring is much higher the suggested flooring is Kota Stone, Granite & Marble Flooring. In this type of flooring following are the steps to lay the above said floors.

1)         First of all a strong rigid substate of filled up soil should be prepared by, filling the soil in layer for not more than 200 mm thickness and to be compacted with mechanical means.

2)         Above sound substrate a 75mm thick layer of plain cement concrete should be laid, the level and line should be maintained to achieve and finished level perfectly.

3)         Now a 150mm thick layer of RCC floor should be laid. The reinforcement for such type of floor should not be less than 0.15% of the gross concrete, sectional area of the concrete. The minimum cement content for floor should not be less than 250 Kg/m³.

4)         Now over all substrate a rich mortar of cement in 1:4 proportions admixed with FAIRPLAST IP and FAIRCRETE RMW should be laid in perfect level & required slope.

5)         Now over laid mortar floor stone should be laid in correspondence to the designed pattern, level & slope. The joints of stone should be sealed with FAIRFIX TG after 24 hours.

6)         If further protection is required coating of SAFECORE AR should be applied to protect the stone layer.

CERAMIC TILE FLOORING :

Ceramic tile should be used in floor where asthetic beauty is required. This

type of flooring should be done in following manner.

1)         Sound substrate should be prepared by filling of earth with heavy

compaction by means of mechanical compaction. 

2)         Now on solid filled up earth a layer of 50 mm thick PCC is required to laid.

3)         Over laid PCC, cement mortar of 1:4 proportion or layer of FAIRFIX TA should be laid to fix the ceramic tile.

4)         Ceramic tile should be fixed in perfect line and level.

5)         Joints of ceramic tile should be filled up with FAIRFIX TG, with the matching shade of tiles after 24 hours of fixing of tiles.

6)         Curing for full 7 days required as the whole the executed work is cement based.

REPAIRING OF STONE FLOORING :

Damaged stone flooring can be repaired in following manner based on the

intensity of damages : a) Light Damages b) Heavy Damages.

a)     Light Damages :

1)         The damaged floor stone/tile should be removed.

2)         The substrate should be made cleaned from any loose particles.

3)         Now on cleaned surface FAIRFIX TA should be laid to fix up the new stone or tiles.

4)         The joints of broken stone or tile should be sealed with FAIRFIX TG.

b)     Heavy Damages :

1)   Due to heavy damage which are the results of settlement of building or earth quake, the existing damaged floor should be removed.

2)   Now if the sub base of flooring is also damaged it also needs repairing. (concrete floor reparing). So it is to be removed completely.

3)   Compaction of floor filler i.e. earth is required if necessary.

4)   New subbase should be laid in accordance with the specification. The thickness of such floor should be kept 75 mm.

5)   Over this subbase now, new flooring should be laid in required line, level & shape. The fixing subbase should be of rich cement mortar of 1:4 proportion with FAIRCRETE RMW or FAIRFIX TA.  

INDUSTRIAL FLOORING :

Flooring of any industrial structural component needs  to  be  looked  after 

very closely at each stage from planning to finishing of  final  layer.

As requirement of flooring in industries varies from just a  flooring   to 

special type of flooring. The industrial flooring  are chemical resistant

flooring,    Abrasion resistant  flooring,  impact  resistant flooring,  anti 

slipping  flooring,  asthetic flooring. These all flooring broadly can be

classified as per following chart.

Concrete floor                 RCC FLOOR

                                    PCC FLOOR

Stone floor                     KOTA STONE FLOOR

                                    MOZAIC FLOOR

                                    CERAMIC FLOOR

                                    MANDANA FLOOR

Resin floor

Chemical resistant floor

CONCRETE FLOOR :

Most of the industries must needs concrete floor either as a finished floor it

self or as a base floor. Where the load coming on the floor   is  not much 

more (light), the Floor should be made with PCC only  . If the load  coming

on  floor is medium or heavy the floor it self or its base should be made

with RCC.

Where PCC floor is laid it should be laid with either 1:4:8 proportion or

1:2:4 proportion with good compaction and leveling. Special care should be

taken for PCC floor as follows.

1)         Minimum cement content should not be less than 330 Kg/m³.

2)         Minimum reinforcement weight in kg per MT should not be less than 0.15% of total cross sectional area of floor.

3)         It should be compacted / vibrated to achieve the maximum possible deuse concrete.

4)         Slump value should be 40mm to 60mm for any RCC floor.

5)         Water cement ratio should be kept to minimum    possible value.

Now on laid sand substrate the top layer of concrete should be made more strong and durable by applying a non metallic floor hardner as a Wearing coat. Depending upon the requirement different type of non metalic floor hardeners are available  as follows.

For heavy duty floor FAIRTOP HD should be used.

For medium duty floor FAIRTOP should    be used.

For light duty floor FAIRTOP STD should be used.

This type of product will give natural out look to the floor of gray color with high abrasion and impact resistance  floor with longer durability. Where floor is suppose to come in contact with oil, chemicals, it should be sealed with sealant like FLOORSEAL, FLOORSEAL PS to make the surface oil resistance. Such sealer also prevents the formation of dust. For better out look coloured FAIRTOP series is also available. Finally for much more abrasion resistant topping SAFECORE series of product can be applied over concrete Surface as per the requirement.

Repairing of Concrete Floor:

Due to old age or excess usage & loading concrete floor may tends to get damaged. Depending or it damages nature, repairing can be done very effectively. Damages may also occur due to settlement of subbase or earth movement due to earthquake.

Damages on floor can be classified as a :

1) Light damages 2) Heavy damages.

1) Light damages :

This type of damages can be repaired as per following steps.

a) Surface preparation : Clean the surface from loose particles, laitance and oil contamintion. The concrete is hacked to a depth of at least 50 to 75 mm and thoroughly  washed   with water to remove all debris, dust etc.

b) Apply one coat of epoxy bonding agent FAIRBOND EP as a primer.

c) Now on a wet primer a layer of ready floor hardner screed of FAIRTOP HD should be laid to require depth and level as per requirement should be maintained.

d) Full 7 days during is to be done over prepared surface.

2) heavy Damages:

Such type of damages should get repaired as per following steps.

a) Surface preparation:  Firstly all the surface where  repairing is to be done should be cleaned perfectly. All loose particles, laitance should be removed. Any oil contamination is found should be removed with FM degreaser . The concrete should be hacked to a depth of at least 50 to 75 mm thick the hacked concrete should be coat cleaned with water jetting.

a)    Application of bonding agent: Make the slurry of FAIRCRETE SBL and

       cement @ 1:3 and apply with a brush on the cleaned surface.

b)    Now on wet bonding agent concrete of M30 grade (1:1:3) with

         FAIRFLO @ 400 ml/bag should be laid to a depth of 50 mm

       thickness. The slump of concrete is to be kept between 40 to 60mm.

c)     On wet concrete non-metallic floor hardner FAIRTOP @ 5 kg/m²

       should be sprinkled and now final finishing should be done.

FLOORING OF CHEMICAL INDUSTRY :

In Chemical Industry the flooring has to be made chemical proof to prevent it from deterioration which occurs due to chemicals. Depending upon the characteristic of the chemical the floor topping is to selected. For heavy chemical resistance and the floor should be coated with SAFECORE VC, for medium chemical resistance the floor should be coated with SAFECORE AR, and for light chemical resistance the floor should be coated with SAFECORE EP (F). This type of coating is to be applied over normal concrete floor. The concrete should be laid as per the requirement.

STONE FLOORING :

From ages the stone is been used as a floor for industries. As the stones are available in bulks through out the India and at the same time its cheaper and more durable it is been used as flooring. In textile industries flooring of kota stone is very common in 19^th century. This type of flooring is durable and gives good natural appearance. In industries where chemical resistant flooring is required Mandana  stone is been used for flooring. But such type of flooring is having its limitations such as, 1) The joints opened up after few years. 2) Weak stone may brake.

But good durable flooring can be achieved by using stone by  following good stone flooring practice.

GOOD STONE FLOORING :

Good stone flooring can be achieved by  following working system.

1) Good sound substrate should be made by filling up good quality of soil in uniform layers; each layer should be compacted to maximum possible density.

2) Over sound sub base a layer of rich concrete of M25 grade or above should be laid. The minimum concrete content for such concrete should be kept minimum to 300 kg/m³. The concrete should be laid by flowing Standard

Concrete  Floor procedure by keeping the workability value from 40 mm to 75 mm.

3) Over sound substrate the stone should be laid with FAIRSCREED TA and subsequently joints should be sealed up with FAIRSCREED TG. This process will also provide chemical resistance of the laid floor.

RESIN BASED FLOORING SYSTEM :

In new age flooring system the floor is been made by various types of resins like epoxy’s, polyurethenes, lapoxyes, metametail epoxy etc. by using such type of flooring materials following type of advantage can be achieved.

a)     Strong permanent bond to concrete base.

b)     Excellent resistance to wide range of aggressive chemicals.

c)      Impermeable to liquids.

d)     Increased toughness, durability, resilience and resistance to impact

        or abrasion.

e)     Hygienic and easily cleaned surfaces.

f)      Greater resistance to cracking.

g)     Low applied thickness.

h)     Rapid installation and curing with minimum disruption to normal

        operation

Resin base flooring can be classified in broadly manner as :

a) Self-smoothening flooring.  B) Resin based screeds.

a) Self Leveling Flooring :

This type of flooring is also called as Self-smoothing flooring or flow applied flooring. This type of flooring is to be applied in 2 to 5 mm in thickness which finally provides perfect glossy finished. This type of floor is a good resistant for  the chemicals of various categories.

b) Resin screed : Various kinds of resins are  been used to make a screed for various  usage  and performance  of  flooring in industries. To achieve such   type of floor epoxy based resin is being used. Majority of epoxy based floor is been used to ensure perfect resistance to high wear and tear along with chemical resistant property. For such type of flooring FAIRSCREED EP is to be used. Depending up on its requirement from various range of product selection of appropriate for required performance can be easily made as per following.

a)     For extra chemical resistant FAIRSCREED ULTRACRETE to be used.

b)     For aggressive chemical and abrasion resistant FAIRSCREED MMA or

        FAIRSCRRED QUARTZ can be used.

If floor with good chemical resistance, FAIRFLO abrasion resistance and better aesthetic out look is required FAIRSCREED ET is to be used.

For application of such type of floor an approved, well-trained contractor is available with Waterproofing 4u. com.

Flooring which are constant touch with spillage of chemicals should be coated with SAFECORE ULTRACOAT or SAFECORE VC. Chart for chemical resistant floors are available at FAIRMATE on request. For light aggressive chemicals coating SAFECORE EP (F) is advisable, which will also provides a good aesthetical out look.

To make the floor dust proof application FLOORSEAL C, SAFECORE AC & FAIRCRETE 16 is advisable.