How to make 3D floors correctly: pouring technology
The technology of manufacturing self-leveling floors with the 3D effect, which has become widespread in industrial and civil construction, has made it possible to significantly expand the possibilities for implementing the most daring design ideas. About how 3D floors are made, and why manufacturing technology requires strict adherence to all operations without exception, will be discussed in this material.
The process of manufacturing floors with three-dimensional images includes three main stages, which, in turn, are divided into several intermediate operations:
- Foundation preparation, which begins with the pouring of the concrete screed and continues with drying, priming and final leveling of the surface;
- Application of the actual decorative coating, when various primers, glazing paints and three-dimensional drawings are used on a self-adhesive basis or applied with a special glue;
- Applying a final protective layer which makes it possible to obtain not only a wear-resistant coating, but also visually increase the depth of the applied image.
Self-leveling floor technology
The technological map for 3D floors indicates exactly which components are used in the performance of a particular technological operation. It details the drying and polymerization time, the time for applying the compositions and the sequence of work. Most often, polyurethane or epoxy-based materials are used for the manufacture of self-leveling floors with a three-dimensional pattern.
Tip: For a durable, wear-resistant finish, it is highly recommended to use 3D floor materials from a single manufacturer that are technically and chemically balanced and provide a complete system that delivers the best quality finished floor.
Foundation preparation
Self-leveling polymer floors are installed on a solid concrete base, which should not have visible and hidden damage, interspersed with separating materials and traces of any contamination, therefore, before making 3d floors, a number of preparatory operations must be carried out:
- Checking the concrete base for damage, which is carried out by visual inspection, tapping the floor surface or using special radio frequency or ultrasonic meters. Modern devices with sufficient accuracy determine the presence of cracks or voids even in a fairly thick layer of concrete;
- Repair of a concrete base with special repair mixtures. In case of significant damage or impossibility of repair, it is necessary to re-make the concrete screed. To ensure maximum floor strength with a small coating thickness, the old base must be destroyed to the state of crushed stone of the middle fraction and then poured a new coating. If the layer thickness does not exceed 40 mm, a special reinforcing mesh is used when installing the screed;
- After repair, the screed must be dried until moisture is completely removed, and the new base must be kept for 28 days with periodic moistening to gain the necessary strength;
- The base intended for drawing 3D images must be absolutely even, without sinks, subsidence and other possible defects. For final leveling, it is best to apply thin-layer self-levelling floors based on cementitious binders, which are applied to a pre-primed screed.
Video showing surface preparation before pouring
drawing
High-quality drawing on the prepared floor surface provides about half the success in the manufacture of three-dimensional floors. The slightest fold or air bubble instantly distorts the picture and destroys the volume of the image. Therefore, before making 3D floors, one should not neglect some additional operations:
- Cleaning, if necessary, washing the floor with special detergents using an industrial vacuum cleaner. Not the slightest grain of debris and not the slightest speck of dirt should remain on the entire surface of the floor;
- Drying the base and applying a special primer that increases adhesion;
- Drawing a picture on a self-adhesive vinyl base or made on special paper and glued to the base with a special glue;
- The final operation after drawing is to control the surface moisture before applying the protective layer. This operation must be approached very carefully. Concrete bases must have a moisture content of no more than 6% to prevent the polymer from peeling off the base.
The video shows the drawing process
Application of a transparent layer of polymer and protective varnish
Protective coatings in the manufacture of floors with three-dimensional images can be based on epoxy or based on polyurethane composites. Moreover, it can be either one or two-component compositions. There are some differences in how 3d self-leveling floors are made on an epoxy or polyurethane basis, but, in general, the technological operations are similar:
- When using any mixture, follow the manufacturer's instructions exactly. When pouring, special attention should be paid to the “survivability” time of the composition, during which it retains the ability to spread;
- When pouring, it is required to prepare the next portions of the composition in a timely manner in order to avoid the appearance of coating heterogeneity and visible steps between the flooded areas of the floor;
- The leveling of the poured mixture is carried out with a special squeegee with an adjustable coating thickness and a needle roller, which serves to improve the spreadability and accelerate the removal of air trapped in the polymer layer;
- To create a shock-resistant wear-resistant coating, depending on the selected polymer, an additional layer of protective varnish can be applied to the floor surface, further increasing the “depth” of the image.
Having completed all the technological operations, it is necessary to withstand the coating for 3-4 days for the final polymerization, after which the floors are ready for use.
You got a rough idea of how 3d self-leveling floors are made. For all the seeming simplicity, the pouring of polymer floors is a rather complicated undertaking that requires well-coordinated actions of the construction team, and precisely adjusted in time. Even after watching a video on how to make 3D floors, you should not take on their device alone, especially with large areas. The slightest inaccuracy can spoil the results of the work done, and it is very difficult to dismantle polymer floors due to their high strength.