Speaker Bio –

• Anupam Shil is working with STP Limited as SBU Head

• 25+ years of working experience with several global and
indigenous companies offering a wide range of engineering
products and services to the Industrial and Infra sector.
• His extensive area of expertise incorporates providing protective 
coating solutions for concrete, metals and pavements for long 
term durability.
Holds a Masters Degree  • Several technical papers and articles written by him has gained 
in Mechanical 
Engineering and  publication in Industry magazines and Engineering Journals.
Business Administration
• Has delivered technical lectures in conferences organized by IEI, 
ICI, BMTPC, Govt. & Pvt. Organizations, Educational 
Institutions…et al.
 CEMENTITIOUS FLOORING SYSTEMS

CONTENT
• Cement Concrete Flooring
• Why another cementitious layer?
• Surface Preparation
• Breathable Cementitious Underlay
• Cementitious Terrazo Flooring
• Insta‐repair of trafficable Concrete substrates
• Epilogue
 CC FLOORING

• Screeds are designed as bonded or unbonded system. However,

current practices do not clearly define the system.
• Usually overlay concrete of 75 to 100 mm is laid on RCC slab with
or without steel reinforcement.
• Finishing process traditionally followed is VDF (Vacuum Dewatered
Flooring) or Truss Screeding followed by power trowelled finish with
hardener or direct finished.

3
 CC FLOORING

9 Challenges:
™ VDF induces curling and warping stresses and induces
stresses on bonding interface.
™ System are not clearly defined as bonded or unbonded and
the principle requirements are clearly missing.
™ Surface preparation for bonded system based on CSP
profile is not followed.
™ Requirements of mechanical and chemical bond is again
missing.
™ Understanding effects of slab deflection of screeds is
unfortunately missing. PT slabs have higher deflection and
joints needs to be designed accordingly including bonding or
shear connectors.

4
 REQUIREMENTS OF CC FLOORING

™ Define whether the system is designed as bonded or

unbonded.
™ If bonded, follow requirements of surface preparation as per
CSP, use of proper bonding agent.
™ Nominal fabric / mesh reinforcement to minimize reflective
cracking.
™ Understand stresses induced due to deflections of base slab
and design joint spacing.
™ Abrasion resistant topping as per the requirment of function.
™ Refer BS 8204 for screed requirements.

5
AREAS OF APPLICATION

6
 FLOORING CONDITIONS

Variety of Conditions that a Flooring is subjected to…

Mechanical Chemical Thermal

• Dynamic • Alkaline • Damp Heat
• Static • Acid • Dry Heat
wPressure • Solvents
wImpact
wGrinding

7
 FLOORING CONDITIONS MATRIX
Typical Stresses subjected to Industrial Floors

8
 FLOORING CONDITIONS MATRIX
Typical Stresses subjected to Industrial Floors
DM Water Plant

Textile Industry

Steel Mill
Machine Repair Workshop

9
 MOTHER SUBSTRATE

+                         ‐
• Inexpensive • Permeable to liquids
• Can be used for a wide • Not resistant to chemical
range of industrial attack
applications • Questionable mechanical
resilience
• Long curing time
• Poor cleanability
FLOORING EXPECTATIONS
 SCREED TYPES

9 OVERLAYMENT:
™ Car Parking
™ Concrete finish floors with polishing
™ Terrazzo systems
™ Industrial floor treatments for wear and tear, chemical
resistance
9 UNDERLAYMENT:
™ In-situ mortar layer of 40-60 mm below stone or tile
finishes.
™ Screed with higher flatness for thin floor toppings like vinyl,
thin large tiles, marbles etc.- Self smoothening systems.
™ Floor level corrections below resin system in industrial
applications.

12
WHY ANOTHER CEMENTITIOUS UNDERLAY?
CURLING – A FLOORING CHALLENGE

14
 DISTRESS – A FLOORING CHALLENGE

• Overtime distress of Concrete Flooring takes place due to,

9 Abrasion
9 Dusting
9 Impact Damage
9 Surface Cracking
9 Joint Failure
9 Structural Overload
9 Chemical Attack
 SURFACE PREPARATION

Checking of Moisture Level

Plastic Sheet
• Cut clear plastic sheeting into a 24" x 24" square
• Tape the plastic firmly to the concrete with duct tape
or any other kind of waterproof tape. Firmly press
down all sides of the tape to prevent moisture from
escaping
• Wait 48 hours and Check the plastic to see if any
moisture has beaded up on the inside of the plastic
Moisture Meter
• Electrical impedance meters are one way to
measure moisture and quickly survey the condition
of a concrete slab
• As internationally accepted, a base having moisture
content of 4% or less only is ready for overlaying.
 SURFACE PREPARATION

Cutting grooves and

filling mortar
• Anchor grooves are required
at free end / termination point
• Minimum double size of
flooring thickness
• Length and width wise every
five meter
 SURFACE PREPARATION

Pot hole repairs

• Cleaning and chipping out of
cracked loosely bound concrete
• Dust removal by air blowing
• Application of Bond Coat (Latex /
Acrylic / Epoxy)
• Rendering with Polymer Repair
Mortars or Epoxy Repair Mortars
 SURFACE PREPARATION

Grinding
• Suitable for epoxy applications
• Remove laitance from the surface up to 100
microns
• Ideally suitable for lesser thickness flooring
system below 2 mm
 SURFACE PREPARATION

Scarification
• Suitable for higher thickness applications
• Use to remove existing epoxy floors
• Remove laitance from the surface 300 to
500 microns
• Ideally suitable for higher thickness
flooring system above 2 mm
 SURFACE PREPARATION

Grit Size for Grinding

• The general rule is to start the
initial grinding with a coarse
30/60-grit diamond and finish with
a 1600- or 3000+ grit diamond,
depending on the exposure level of
aggregate and gloss level
required.
 SURFACE PREPARATION

Shot Blasting
• Suitable for higher thickness
applications
• Used to remove existing epoxy floors
• Remove laitance from the surface 300
to 500 microns
• Ideally suitable for higher thickness
flooring system above 2 mm
 SURFACE PREPARATION
The most effective reference tool for determining concrete surface profiles is the molded rubber comparator
chips, available from the International Concrete Repair Institute. These samples replicate ten grades of surface
roughness, and are designed for direct visual and tactile comparison to the concrete surface in question.
There is no definitive text description for the ten grades: the comparator is the standard. However, ICRI does tell
us how much surface profile is sufficient for various types of coatings and overlays:
 PRIMERS Vs CEMENTITIOUS UNDERLAYS

• Regular thin film sealing primers

often is unable to sustain whenever
presence of moisture (and
entrapped salts) in the substrate is
high
• VS – 50 to 100%
• Film thickness – 50 to 200 microns

• Epoxy modified cementitious underlays

act as Temporary Moisture Barrier
(TMB) when applied at minimum 2 mm
thick and a provides a self
smoothening screed
• This provides a reliable base for laying
of resinous floorings, like, Epoxy, PU,
or PMMA
 CEMENTITOUS BREATHABLE UNDERLAY

• A three part epoxy modified

cementitious fine textured mortar
for self smoothing floors
• Excellent adhesion to concrete and
screeds
• Acts as suitable floor topping on
non-ventilated damp substrates
without much aesthetic
requirements
• Tolerates up to 100% relative
humidity in concrete
• Can also be used for repair and
maintenance of monolithic and
vacuum concrete floors
• Can be used as a protective
screed in new work or repairs, in
aggressive chemical environments
• Can be built from 2 up to 8 mm
 CEMENTITOUS BREATHABLE UNDERLAY
• Prevents osmotic blistering of resin
based floors after 24 hours
• It is economic and easy to apply
• Good chemical resistance
• Contains no solvents
• Resists frost and de-icing salts
• Will not corrode reinforcement
steel
• Impervious to liquids but
permeable to water vapour
• Excellent early and final
mechanical strengths
• Meets Class R4 of EN 1504-3
(Guideline for structural and
non-structural repair mortar)
 EN 1504-3 Guideline for Repair Mortars
Requirement
Performance Test method Non-structural Structural
characteristics
Class R1 Class R2 Class R3 Class R4
Compressive Strength BS EN 12190 ≥ 10MPa ≥ 15MPa ≥ 25MPa ≥ 45MPa
Chloride Ion Content BS EN 1015‐17 ≤ 0.05% ≤ 0.05% ≤ 0.05% ≤ 0.05%
Adherence Bond BS EN 1542 ≥ 0.8MPa ≥ 0.8MPa ≥ 1.5MPa ≥ 2.0MPa
Contrasted Expansion /  BS EN 12617‐4 No requirement Bond strength after test ≥  Bond strength after test ≥  Bond strength after test ≥ 
Shrinkage 0.8MPa 1.5MPa 2.0MPa
Durability – Resistance to  BS EN 13295 No requirement dk ≥ control concrete
Carbonation (concrete of reference type MC 0,45)
Modulus of Elasticity BS EN 13412 No requirement No requirement ≥ 15GPa ≥ 20GPa
Thermal Compatibility:  BS EN 13687‐1 Visual inspection after 50  Bond strength after 50  Bond strength after 50  Bond strength after 50 
Freezing‐thawing cycles cycles ≥ 0.8MPa cycles ≥ 1.5MPa cycles ≥ 2.0MPa
Thermal Compatibility:  BS EN 13687‐2 Visual inspection after 30  Bond strength after 30  Bond strength after 30  Bond strength after 30 
Storms cycles cycles ≥ 0.8MPa cycles ≥ 1.5MPa cycles ≥ 2.0MPa
Thermal Compatibility Dry  BS EN 13687‐4 Visual inspection after 30  Bond strength after 30  Bond strength after 30  Bond strength after 30 
cycles cycles cycles ≥ 0.8MPa cycles ≥ 1.5MPa cycles ≥ 2.0MPa
Slip Resistance BS EN 13036‐4 Class I: > 40 units with damp test
Class II: > 40 units with dry test
Class III: > 55 units with damp test
Thermal Expansion  BS EN 1770 Not required if tests 7, 8 or 9 are carried out, otherwise declared value
Coefficient
Capillary Absorption  BS EN 13057 No requirement ≤ 0.5kg∙m‐2∙h‐0.5
(permeability to water)
 CEMENTITIOUS SELF LEVELLING UNDERLAY

• Single component polymer modified

cementitious self-levelling underlay
for smoothening uneven concrete
floor in a durable way
• Does not provide a wearing surface
but provides an underlay for wooden
/ PVC / Carpet / Tile / Marble floors
• Recommended thickness range, 3 to
25 mm
• Theoretical Coverage for 25 kg bags
o 3 mm – 4 m²
o 12 mm – 1.8 m²
o 25 mm – 0.61 m²
 CEMENTITIOUS SL TOP SCREED

• DIN EN 13813 – SCREED MATERIAL AND FLOOR SCREEDS – SCREED MATERIALS – PROPERTIES AND REQUIREMENTS
 CEMENTITIOUS SL TERRAZZO SCREED

• Self-levelling, ultra fast setting

cementitious system to create
polished floors with a Terrazzo effect
• Applied in 15 – 40 mm thick layers
• Ideal for shopping centres, show-
rooms, schools, museums, theatres,
shops, offices, apartments, etc.
• Thick layer of natural aggregates
blended with pigmented binders to
achieve several colour choices
• Colour pattern shall remain uneven,
typical of cementitious products
• Final polishing done using dry
technique using diamond tools
• Complies to the standards set by
EN 13813
 METHOD SEQUENCE

Checking of  Cutting  Mechanical 

Moisture  Cleaning Grooves &  Grinding / 
Level Filling  Mortar Scarification

Laying Natural 
Vacuum  Priming  …Quartz 
Aggregates w/ 
Cleaning followed by… Broadcasting
Binder

Self‐levelling  Polishing & 
Final Polishing 
Hydraulic  Porosity 
& Anti‐stain  Waxing 
Binding  Sealing w/ 
Coating
Mortar Grout 
 METHOD SEQUENCE

• Self-levelling, ultra fast setting cementitious system to produce polished Terrazzo floors

STEP-1: Primer followed by quartz broadcasting STEP-2: Laying on Natural Aggregates with Binder

STEP-6: Waxing to make STEP-5: Anti-stain STEP-4: Grout with STEP-3: Mortar with
the final finish coating Hydraulic Bonder Hydraulic Bonder
 RESULTS – CEMENTITIOUS SL TERRAZZO SCREED

AFTER 28 DAYS:
Compressive Strength ≥ 55 N/mm²

Flexural Strength ≥ 10 N/mm²

 DISTRESS ON TRAFFICABLE CONCRETE SUBSTRATE

REPAIR CHALLENGES
• Open time for repairs
• Physical properties (strength, deflection, abrasion)
• Chemical properties (exposure to acids, alkalies...)
• Temperature (stability through temp. cycling)
• Weatherability (UV & Rains)
• Bonding
• Compatibility (Physical & Chemical compatibility with mother
susbtrate)
 INSTA-REPAIR OF TRAFFICABLE CONCRETE
ƒ Three component, cold applied chemistry, compounded to develop high
strength and to promote easy bonding to both concrete and steel for high
performance concrete substrate

ƒ Repair cracks ranging between 5 – 50 mm wide on concrete substrates

ƒ Self-levelling – Easy Workability

ƒ Permanent Repair Solution

ƒ Fast Curing – Accepts traffic in an hour

ƒ Elongation after 7 days, 45 ± 5% (ASTM D 412)

ƒ Compression (ASTM D 695)

4 hrs. 3 MPa
24 hrs. 11 MPa
 INSTA-REPAIR OF TRAFFICABLE CONCRETE

APPLICATION
VIDEO

(I) Surface Preparation (II) Vacuum Cleaning (III) Cleaned & Masked

(IV) Primer Application (V) Ready for Pouring (VI) Pour Elastomeric Concrete
 EPILOGUE

SUMMARIZING

• Define System Type and it’s Functional Requirement

• Why another cementitious layer? – To provide functional floor, levelness and Stop
Osmotic Blistering
• Surface Preparation – Contractor’s Proficiency and use of Correct Machinery
• Breathable Cementitious Underlay – Before Resin Floorings on Damp Concrete
• Cementitious Terrazo Flooring – Durable Flooring with Aesthetic Appeal
• Instant Repair of trafficable Concrete substrate – With Elastomeric Concrete
Thank You !