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In the same construction environment, using identical construction techniques, variations in the base concrete (including fine-grained concrete) can significantly influence the quality of the cement wear-resistant floor (factors such as color, strength, and abrasion resistance). To ensure optimal results when working with Sika hardener products, we suggest the following guidelines for preparing the base concrete:
First, manage the bleeding of the concrete.
After vibration, the bleeding rate should be kept below 2%. Excessive bleeding presents several challenges:
- The surface becomes weaker and less abrasion-resistant.
- Additives like fly ash tend to rise to the surface, affecting the visual finish.
- Floating additives might create a barrier layer, reducing the bond between the hardener and the concrete, potentially causing delamination.
Second, regulate the amount of fly ash.
High-quality water reducers can help eliminate the need for fly ash or limit its usage to no more than 5%. When bleeding occurs, fly ash can lead to "black spots" appearing on the wear-resistant floor's surface.
Third, avoid incorporating mineral powder.
Mineral powder should be omitted from the concrete mix as it increases the risk of delamination in the wear-resistant floor.
Fourth, control the slump.
To maintain the quality of the wear-resistant floor, the slump should remain minimal. The batching plant should adjust according to temperature and transport distance, keeping the slump of the concrete within 100 mm. For pumped concrete, the slump should be controlled at 120 mm ± 10 mm. Once delivered, no additional water should be added.
Fifth, avoid air-entraining agents.
The use of air-entraining agents in concrete will inevitably result in blistering and delamination in the wear-resistant floor. Therefore, their use is discouraged.
Sixth, avoid early-strength antifreeze agents.
Most early-strength antifreeze agents are sodium sulfate-based, which can cause the cement surface to whiten upon hardening (a phenomenon known as "alkali-silica reaction"). If color sensitivity is an issue, particularly with colored floors (like green), these agents should be avoided.
Seventh, ensure proper water quality.
Potable water should be used for mixing, adhering to the current "Standard for Concrete Mixing Water" (JGJ63). Using alternative water sources (e.g., groundwater or river water) may compromise the wear-resistant floor.
Eighth, control the strength of the concrete.
The concrete grade should not fall below C25 nor exceed C30.
Ninth, manage aggregate content.
Avoid using concrete mixes containing sedimentary aggregates. This could lead to blistering or delamination in the wear-resistant floor.
Tenth, additional considerations for fine-grained concrete.
When applying hardeners to a fine-grained concrete layer, beyond the aforementioned recommendations, keep these points in mind:
- The entire cast layer should be at least 60 mm thick.
- An interface agent (such as Sikadur 32 LP) is recommended during the pour.
- It’s important to note that the color of the wear-resistant floor can be influenced by the base concrete. For high-color requirements, consider creating a larger test panel on-site to assess the final color.
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