Since 2004, Concrete Solutions Inc. (CSI) has helped contractors and building owners achieve faster turnover timelines by refurbishing existing damaged concrete floors and making them like new with cementitious self-leveling materials.
Self-leveling materials are divided into two main groups – overlayments and underlayments.
Overlayments, or toppings as they are sometimes referred, can be dyed, stained, and polished, producing an infinite number of finishes. New and improved overlayment products will accept aggregate broadcast applications for a unique finished floor aesthetic. Overlayments are designed to be a finished and usable floor.
Underlayments are installed to provide a smooth and flat surface for the installation of another flooring such as tile, epoxy coatings, hardwood, and sheet flooring goods. They can typically be walked on within 3 hours and new flooring can be installed within 24-48 hours, thus shortening construction timelines and schedules. Your existing facility may have a floor which over time has become worn, or you are taking over a new office or retail space where the existing floor is just too damaged to install new flooring. Self-levelers can be the answer for you.
CSI has long-standing relationships and successful installation track records with North America’s leading manufacturers of self-leveling materials including Mapei, Ardex, Sika, Custom Cements, CTS Rapid Set, and many others. Our installation teams are certified by each individual manufacturer and further participate in regular online and in house training programs to keep up to date with new products and installation techniques.
CSI has completed numerous industrial, institutional, and warehouse projects where tight floor tolerances were imperative for equipment and machinery to function properly. Prior to the installation of self-leveling products, a moisture mitigation system is installed if there is moisture vapor or high relative humidity levels present in the substrate.
Our team of professionals will assess your project and make recommendations based on our findings to ensure a successful installation.
Frequently Asked Questions
What is the process for installing self-leveling materials?
All self-leveling materials must be installed over a mechanically prepared substrate. The recommended Concrete Surface Profile or CSP must be achieved on the underlying substrate by shot blasting or diamond segmented grinding. Once properly prepared the substrate is tested for Moisture Vapor Transmission and Relative Humidity to ensure the priming coat meets the conditions inherent within the substrate to ensure a solid bond. Once the substrate has been primed, self-leveling materials can be either pumped with specialized equipment or barrel mixed and hand-applied. Gauge raking and detailing are critical finishing steps to ensure a smooth and flat surface.
Can self-leveling materials be installed over other floor types in addition to concrete?
Yes. All manufacturers have specific requirements and specifications for installations over different types of flooring. Technical data must be followed to ensure a successful installation.
What is the maximum thickness of self-leveling materials that can be applied?
For most applications, 1.5 inches is the maximum thickness per application. Pea gravel can be added to the self-leveling material for areas requiring a greater thickness, or a second lift over the first can be installed.
Can I use one of the self-levelers as a walk or wear surface?
Yes, there topping products available that can be used as a wear surface rather than an underlayment for other floor coverings.
Can we have a “level” floor installed?
Yes, you can, but the real question should be: “do I need a level floor or just a flat smooth floor?”
Self-leveling systems can correct uneven floors, repair damaged concrete, level existing surfaces, and provide a smooth and durable new substrate for decorative flooring treatments.
Self-leveling underlayments are used to level uneven, grooved, and /or heavily pitted floors in order to make them stable, flat, and level, suitable for other applications such as ceramic tile, hardwood, etc. Self-leveling overlayments are suitable toppings for decorative concrete floors.