Self-levelling preparation and finishing mortars - XTREMFLOOR®

The self-levelling mortar is composed of cement, anhydrite, fine sand and other special additives. It is precisely its additives that give it the fluidity it boasts and that causes the final finish to be smoother and more level. In short, a mortar much more liquid than the rest that makes it unique.

A composition that gives it excellent thermal conductivity and a exquisite uniform finish, among many other virtues that we will delve into later.

As answered in previous questions, the self-levelling mortar is used to level, adapt and improve the base of the support on which the mortar is subsequently poured. Continuity and uniformity in the resulting surface is sought.

The self-levelling mortar is a very versatile product, being able to be used in different fields of application depending on the individual needs and requirements of the project. In all of them, this mortar will help to level and adapt the work support to be able to place another coating afterwards. That is, it will create a solid base to later apply ceramics, microcement, epoxy systems, etc.

Although most self-levelling mortars are for indoor use, there are some mortars suitable for being outdoors. Be that as it may, it is a valuable resource in modern construction and has a wide variety of uses in both residential projects and commercial and industrial projects.

- Floor preparation: self-levelling mortar is mainly used to level those floors that are deteriorated or have irregularities, then to install tiles, ceramics, laminates, wood, microcement... This way, a flat surface is obtained where the aesthetics and durability of the finish are improved.

- Levelling of screeds: in construction projects, self-levelling mortar helps with the levelling and correction of imperfections in concrete screeds. A very important point to, for example, facilitate the subsequent installation of radiant floors.

- Sports courts and other areas: self-levelling mortar forms one of the most efficient solutions for creating sports court pavements such as those of football, basketball or tennis.

- Staircase repair and renovation: Uneven steps? Self-levelling mortar is an excellent option to solve it and improve the safety of people.

- Floor repair: in those spaces that suffer from greater wear, such as industrial and commercial areas, self-levelling mortar emerges to restore and level these pavements. In this way, the lifespan of the floor is perpetuated and the safety of the workplace as well as garages and car parks is improved.

- Great material compatibility: ceramics, stone, vinyl or laminated flooring, wood, epoxy and industrial systems, microcement, cement, concrete, anhydrite, wood...

The self-levelling mortar is a product that enjoys countless advantages such as excellent adhesion and levelling capacity. Likewise, it is a very hard mortar because it does not crack or split and it takes very little time to harden. After 3 or 4 hours, as a general rule, it can be walked on without problems (light traffic).

Another of its benefits is that it can be used both in a new construction and in rehabilitation projects of previously existing supports. Not to mention that it configures more compact pavements and free of air bubbles. Factors that validate the success that this material treasures.

A pavement suitable for the installation of underfloor heating and with a high mechanical resistance and to abrasion. Its low maintenance and its fantastic quality-price ratio make self-levelling mortar a highly demanded system.

Broadly speaking, the self-levelling ability and special properties are the two elements that differentiate a self-levelling mortar from a conventional mortar. While the former is more suitable in situations where a more precise and effective levelling is required, the latter is used in applications where there is a greater margin regarding levelling and where more manual work is required.

1. Self-levelling: the self-levelling mortar is specifically formulated so that when poured onto a surface it levels itself automatically. This means that it does not require exhaustive manual manipulation or special tools to level the support. The opposite case of a conventional mortar in which a significant effort in this sense is required to achieve good levelling.

2. Special additives: the additives incorporated into the self-levelling mortar are designed to give it greater fluidity and self-levelling. In contrast, conventional mortar does not usually include these additives.

3. Specific applications: for precise levelling only a self-levelling mortar is suitable. If this point is not essential in the project, a conventional mortar can also be used.

4. Time saving and efficiency: the self-levelling mortar translates into a time and labour saving compared to conventional mortar, as the process is less laborious and not as many special tools are needed.

Each mortar has specifications from the manufacturer that must be followed to carry out a correct installation. The quantities of product, its kneading and drying hours, etc, vary depending on the brand. However, generally, these are the steps that need to be taken to prepare and apply a self-levelling mortar.

Clean the work surface

If the surface on which work is to be carried out is not in optimal conditions, the coating cannot be properly executed. Therefore, it is necessary to ensure that there is no dirt, grease, dust or excess water.

Prime the surface before applying the mortar

It is highly recommended to use a primer that promotes and improves the adhesion of the self-levelling mortar. In our case, we advise using our anti-humidity primer Primapox®100 Barrier with aggregate saturation. For uniform coverage, let it act and dry for about 24 hours.

Prepare and knead the mortar

In a bucket add 4.5 litres of clean water. Then gradually add the mortar and mix both components well with an electric whisk or with a pumping machine (if possible).

Apply the mortar on the surface

Once a homogeneous and lump-free mixture is obtained, pour the self-levelling mortar onto the work surface. We suggest starting from the deepest unevenness of the support.

Respect the drying time of the mortar

The setting of the self-levelling mortar is very fast. You will hardly have to wait a few hours, between 3 and 4, for it to dry completely. Although the final time will depend on the environmental conditions and the product.

Seal if required

In the case of using a self-levelling mortar as a final finish, as is the case with XTREMFLOOR® Level Decor, proceed to seal with a varnish specific for such effects.

The time it takes for a self-levelling mortar to dry and harden depends on the quality of the product. The manufacturers are the ones who have to specify that time in the corresponding technical sheets. As a general rule, it is usually between 24 and 48 hours.

As for the self-levelling mortars of the XTREMFLOOR® family, we can assure that they are very fast drying products. Systems that harden in a short time.

On one hand, there are self-levelling mortars in thin layer and, on the other hand, self-levelling mortars in thick layer. In this sense, the thickness depends on what type of product is finally used. At Topciment® we have several types of layer thickness: from 1 to 10 millimetres (XTREMFLOOR® Level Concrete) and from 5 to 20 millimetres (XTREMFLOOR® Level Industrial and XTREMFLOOR® Level Decor). The choice of one or the other will depend on the type of finish you want to achieve as well as the support to be coated.

Not all self-levelling compounds are suitable for outdoor use; in fact, they are usually used indoors. However, there are some special self-levelling compounds that are optimal for outdoor applications. The mortars from the XTREMFLOOR® range can only be used indoors.

The resistance of the self-levelling mortar is subject to the formulation of each product individually, as the additives that are added in each one of them are the ones that ultimately offer one type of compressive resistance or another.

Taking this into account, the compressive strength of the self-levelling mortar ranges between 20 and 40 MPa (megapascals). These figures allow these systems to be suitable for application in areas subjected to intense pedestrian, vehicular or industrial traffic. In addition, this mortar also has a great resistance to flexural strength and chemical agents.

Two aspects need to be differentiated. Firstly, the lifespan of the self-levelling mortar from its manufacture, which is usually around 9 months as is the case with our XTREMFLOOR® system. And secondly, the workability time it has once the mortar has been mixed.

In this regard, the lifespan of the self-levelling mortar once it is mixed with water depends on the ambient temperature and the support as well as the components and the quality of the product in question. Specifically, for XTREMFLOOR® the workability time at 20ºC is 20 minutes.

Both options are correct. Self-levelling mortar sometimes requires another coating, as is the case with XTREMFLOOR® Level Concrete and XTREMFLOOR® Level Industrial. But in other circumstances, it can be used as a final finish with products like XTREMFLOOR® Level Decor.

Not only can a radiant heating system be installed after the application of a self-levelling mortar, but it is a fairly common combination in renovation and construction projects. A possibility that is due to the versatility that this product treasures, like our self-levelling mortars from the XTREMFLOOR® line.

Now, it is important to follow the manufacturer's recommendations and have experienced professionals carry out this procedure so that the installation of both systems is successful. Since a start-up protocol must be followed rigorously.

Each mortar has intrinsic characteristics that define its performance per square metre. Generally speaking, the performance of a self-levelling mortar is between 1.5 and 2 kg per m²/mm.

In the particular case of our products, the consumption is:

- XTREMFLOOR® Level Concrete: 1.8kg / m²/ mm.

- XTREMFLOOR® Level Industrial: 1,670 kg / m²/ mm

- XTREMFLOOR® Level Decor: 1,670 kg / m²/ mm

With the average performance we just saw, if a job of about 50m² with an approximate thickness of 5 mm had to be carried out, approximately 17 bags of 25 kg self-levelling mortar would be needed.

There are various classifications on the types of self-levelling mortars depending on which element is analysed to make the diversification.

According to the role it plays in the installation of the cladding, we find:

- Self-levelling preparation mortars: they are used as a primer for the coating that is applied next and that will provide the final finish to the surface. Like XTREMFLOOR® Level Concrete and XTREMFLOOR® Level Industrial.

- Self-levelling finishing mortars: it acts as the final material that is placed on a previously existing support to fulfil an aesthetic function and, in addition, to protect the previous coating. This is the case with XTREMFLOOR® Level Decor.

According to the binder that it incorporates in its formulation, we have:

- Self-levelling cement mortars.

- Self-levelling mortars of calcium sulphate.

- Magnesite self-levelling mortars.

- Self-levelling mortars of asphaltic putty.

- Self-levelling synthetic resin mortars.

According to the thickness of the layers, we distinguish:

- Self-levelling thin-layer mortars: the final thickness ranges between 2 and 30 mm. Our XTREMFLOOR® mortars would be here.

- Thick layer self-levelling mortars: here we find mortars whose layer thickness exceeds 35 mm.

At Topciment® we manufacture all the products that we market in our respective factories in Valencia, Spain. We have total control of the entire process: from the selection of the highest quality raw materials and the formulation of the systems by our own laboratory team, to the production of the product, its subsequent packaging and distribution. Highest standards of quality that are recognised in the ISO 9001:2015 certificate that we have held for years.

For all these reasons, if you want to buy quality self-levelling mortars you are in the right place. Contact our technical service and we will advise you on the product that best suits your needs, as well as provide you with a personalised quote at no cost.

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