Construction Technology for Corundum Abrasive Wear-Resistant Materials
Release Time:
2016-08-26
Source:
Construction Technology for Corundum Abrasive Wear-Resistant Materials
Emery abrasive flooring is a dry-spread, factory-premixed, ready-to-use flooring material that can be applied directly on-site. It is available in a variety of colors, including red, yellow, green, and gray, and is primarily composed of natural minerals, making it highly environmentally friendly. When applied directly to the surface of concrete during its initial setting stage, it forms a hard, dense, dust-free, aesthetically pleasing, and exceptionally wear-resistant floor. Its seamless integration with the underlying concrete slab results in a short installation period, excellent durability, and reduced long-term costs associated with periodic resurfacing or thickening. Moreover, it can be customized in a wide range of colors to meet aesthetic requirements. With advantages such as minimal dust generation, easy cleaning, low cost, simple application, long service life, and superior resistance to abrasion and impact, emery abrasive flooring is an ideal replacement for terrazzo flooring.
Construction Process
1 Layout of the polished surface
Based on the building’s structural reference chalk lines (e.g., the 50 cm wall line), use a level to establish the designated concrete placement thickness within the floor-concreting area, set horizontal elevation markers, and conduct thorough verification to ensure that the maximum unevenness does not exceed 3–5 mm.
2 Concrete Pouring
(1) Prior to concrete placement, water the foundation surface to ensure it is thoroughly moistened. (2) Place the concrete in a single pour whenever possible to the specified elevation; for any areas that do not reach the design elevation, top up with additional concrete and compact it by vibration, but absolutely prohibit the use of mortar for patching. Use a plate vibrator for compaction, followed by multiple passes with a specially designed steel roller. At columns, edges, and corners, apply a finishing trowel finish using a wooden float. After leveling the concrete, the cement paste must rise to the surface to a thickness of at least 3 mm. (3) Upon completion of concrete placement, remove bleed water using rubber hoses or vacuum equipment, repeating the process at least twice before commencing the application of the wear-resistant material. During the intermediate stage of work, personnel shall wear flat-soled rubber shoes when entering the area; during the final stage, they shall wear waterproof paper shoes.
3 First application of wear-resistant material, followed by troweling and polishing
(1) The timing of wear-resistant material application varies depending on factors such as climate, temperature, and the concrete mix proportion. Applying it too early can cause the material to sink into the concrete, rendering it ineffective; applying it too late, when the concrete has already set, will result in loss of bond strength, preventing the material from adhering and leading to delamination. To determine the optimal time for application, step on the surface—when it sinks about 5 mm, the first spreading operation may commence. (2) At edges such as walls, columns, door frames, and formwork, moisture evaporates more rapidly; therefore, these areas should be treated first to prevent reduced effectiveness due to water loss. (3) The initial application accounts for two-thirds of the total dosage, and the mixture should be spread evenly without being thrown or tossed, which could cause segregation. Following spreading, the surface should be smoothed immediately with a wooden trowel. After the wear-resistant material has absorbed some moisture, it should then be compacted and dispersed using a power trowel, allowing it to integrate with the underlying concrete paste.
4 Second application of wear-resistant material, followed by troweling and polishing
(1) During the second spreading, first use a straightedge or a flat screed to check the levelness and correct any uneven areas from the first spread; the direction of the second spread should be perpendicular to that of the first. (2) The amount of material used for the second spread should be one-third of the total dosage. Immediately after spreading, smooth and polish the surface, and repeat the polishing machine operation at least twice. When operating the polishing machine, proceed in both longitudinal and transverse directions in an alternating pattern, ensuring uniformity and order to prevent material accumulation. Edges and corners should be finished with a wooden trowel. (3) Once the surface layer has hardened to the point where it yields slightly under finger pressure, adjust the speed and angle of the polishing machine according to the degree of hardening, and perform at least three passes in both longitudinal and transverse directions. (4) The flatness requirement for wear-resistant flooring is a maximum deviation of 3–5 mm within a 2 m square area, with the maximum difference between the highest and lowest points at the same elevation not exceeding 20 mm. Cracking, delamination, and sanding-off should be minimized as much as possible.
5 Surface Modification and Curing
(1) After troweling with the power trowel, irregular trowel marks may still remain on the top layer. To eliminate these marks, a thin steel trowel is used for orderly, unidirectional manual burnishing of the surface layer, thereby completing the finishing operation. (2) Five to six hours after the application of the wear-resistant floor coating, a curing agent shall be sprayed at a dosage of 0.2 liters per square meter, or the surface shall be covered with plastic film to prevent cracking. (3) Formwork may be removed 24 hours after completion of the wear-resistant floor topping work; however, care must be taken to avoid damaging the edges of the floor. (4) Cutting joints should be constructed 5–7 days after completion to prevent irregular cracking; the spacing between joints is recommended to be 6–8 meters (typically determined based on the column spacing in the workshop). All cutting joints must be marked out uniformly to ensure neat and straight lines, and the cutting depth should be at least one-fifth of the floor thickness. The joint-filling material shall be preformed or cut elastomeric resin materials; sealant is recommended.
