Cement-based Self-leveling Mortar Construction Technology

Cement-based self-leveling mortar is commonly used in construction for achieving flat and level surfaces. Here is a step-by-step guide to the construction technology involved in the application of cement-based self-leveling mortar:

1. Surface Preparation:

• Clean the Substrate: Ensure that the substrate (concrete or existing flooring) is clean, free of dust, grease, and any contaminants.
• Repair Cracks: Fill and repair any cracks or surface irregularities in the substrate.

2. Priming (if required):

• Primer Application: Apply a suitable primer to the substrate if needed. Primer helps improve adhesion and prevents the self-leveling mortar from drying too quickly.

3. Setting up Perimeter Formwork (if required):

• Install Formwork: Set up formwork along the perimeter of the area to contain the self-leveling mortar. Formwork helps to create a defined boundary for the application.

4. Mixing the Self-Leveling Mortar:

• Select the Right Mix: Choose the appropriate self-leveling mortar mix based on the application requirements.
• Follow Manufacturer’s Instructions: Mix the mortar according to the manufacturer’s instructions regarding water-to-powder ratio and mixing time.

5. Pouring the Self-Leveling Mortar:

• Start Pouring: Begin pouring the mixed self-leveling mortar onto the prepared substrate.
• Work in Sections: Work in smaller sections to ensure proper control over the flow and leveling of the mortar.

6. Spreading and Leveling:

• Spread Evenly: Use a gauge rake or a similar tool to spread the mortar evenly across the surface.
• Use a Smoother (Screed): Employ a smoother or screed to level the mortar and achieve the desired thickness.

7. Deaeration and Smoothing:

• Deaeration: To eliminate air bubbles, use a spiked roller or other deaeration tools. This helps in achieving a smoother finish.
• Correct Imperfections: Inspect and correct any imperfections or irregularities in the surface.

8. Curing:

• Cover the Surface: Protect the freshly applied self-leveling mortar from drying too quickly by covering it with plastic sheets or wet curing blankets.
• Follow Curing Time: Adhere to the manufacturer’s recommendations regarding curing time. This ensures proper hydration and strength development.

9. Finishing Touches:

• Final Inspection: Inspect the cured surface for any defects or unevenness.
• Additional Coatings (if required): Apply additional coatings, sealers, or finishes as per project specifications.

10. Removal of Formwork (if used):

• Remove Formwork: If formwork was used, carefully remove it after the self-leveling mortar has sufficiently set.

11. Flooring Installation (if applicable):

• Adhere to Flooring Requirements: Follow the specifications provided by flooring manufacturers regarding adhesives and installation procedures.
• Check Moisture Content: Ensure that the moisture content of the self-leveling mortar is within acceptable limits before installing floor coverings.

Important Considerations:

• Temperature and Humidity: Pay attention to temperature and humidity conditions during application and curing to ensure optimal performance.
• Mixing and Application Time: Self-leveling mortars typically have a limited working time, so it’s crucial to mix and apply them within the specified time frame.
• Thickness Control: Follow the recommended thickness guidelines provided by the manufacturer. Adjustments may be needed based on the specific requirements of the project.
• Quality of Materials: Use high-quality self-leveling mortar and adhere to the specifications provided by the manufacturer.
• Safety Measures: Follow safety guidelines, including the use of personal protective equipment (PPE) and ensuring proper ventilation during application.

Always refer to the technical data sheets and guidelines provided by the manufacturer of the self-leveling mortar for specific product information and recommendations. Additionally, consider consulting with construction professionals for complex projects or if you encounter any challenges during the application process.