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Dry-shake hardeners for concrete floors are typically spread onto freshly poured concrete surfaces to both color the surface and increase its resistance to abrasion.
Dry-shake hardeners for concrete floors are typically spread over freshly poured concrete surfaces. This not only imparts color to the surface but also enhances its abrasion resistance. By improving abrasion resistance and reducing surface permeability, these hardeners mitigate some common negative attributes of plain concrete such as dusting and liquid absorption. This method offers a cost-effective and quick way to enhance concrete floors.
Dry-shake hardeners are pre-mixed materials applied to freshly poured concrete floors to enhance their surface abrasion resistance.
After leveling the freshly poured concrete, Dry-Shake Hardened powder is sprayed onto the concrete surface. The key to their effectiveness is the presence of some moisture on the concrete surface. This moisture allows the cement binder in the hardening spray to activate and bond with the underlying concrete. This process creates a denser and more abrasion-resistant surface layer.
During the curing process, the dry-shake hardener powder consumes a portion of the moisture from the fresh concrete. This can be beneficial as it helps to reduce the overall water-to-cement ratio (w/c) near the surface, resulting in a stronger and more durable concrete surface.
All industrial, factory, and warehouse floors require a high-quality surface that ensures long-term durability, high abrasion resistance, dust-proof properties, low permeability, and safety. In most industrial applications, dry-shake hardeners offer the best value for money compared to other concrete finishing or coating methods. The most important features and benefits offered by dry-shake hardeners include:
The process of applying the Dry-Shake Hardened powder directly onto the fresh concrete allows for a one-step, simultaneous finishing of the surface during the concreting operation. The concrete floor, integrated with the structural slab, becomes foot-trafficable within 12 to 24 hours of pouring, and light use can commence after three to seven days.
Hardening powder-applied floor coatings offer a cost-effective solution for flooring, providing an excellent value for money. The initial costs of materials and labor required for installation are comparatively lower than other methods. Additionally, due to the high durability of these floors, maintenance costs are reduced, and their long lifespan minimizes downtime and the expenses associated with floor failures. Overall, dry-applied hardening powders result in cost savings both in the short and long term.
Dry-shake hardeners significantly enhance the durability of industrial floors. By creating a highly resistant top layer and improving adhesion to the underlying concrete, these hardeners reduce wear and tear. This results in lower maintenance costs, less downtime, and a longer overall lifespan. The reduced porosity also improves the floor’s resistance to chemicals and stains. Because of these benefits, dry-shake hardened concrete floors offer a strong return on investment and are increasingly favored in life cycle assessments.
The predominant color for floors treated with dry-shake hardeners is gray. For many years, aesthetics in industrial buildings were not a significant concern. However, due to their impact on employee morale and company image, aesthetics have gained more importance. Dry-shake hardeners not only enhance the performance of floors but can also play a role in the aesthetic design of facilities.
These hardeners are available with mineral pigments in a wide range of colors, including very light shades like yellow and white. Reflective floors can brighten workspaces, improve worker productivity, and reduce lighting costs. Due to the increased aesthetic value of dry-shake hardened concrete, their use has expanded to public buildings and private homes.
In all types of applications, including wet, dry, and contaminated environments, floor surfaces should contribute to creating a safe working environment. Slips and falls often occur due to the presence of contaminants on the floor. An anti-slip floor relies on a combination of providing a surface with adequate friction and efficient maintenance.
Applying dry-shake hardeners is a safe and environmentally friendly method. These materials have low levels of volatile organic compounds (VOCs), contributing to fire safety and human health. Additionally, maintaining dry-shake concrete floors is easy, and standard cleaning equipment can be used. If necessary, protective coatings can be applied for added dust resistance, making the environment more hygienic and easier to use.
Dry-shake hardeners for concrete are primarily classified into three groups based on the type of aggregate used in them.
The proportion of aggregates in Dry-Shake Hardened concrete hardener powders can vary from 100% of a single group to a combination of several or all of them. Different proportions in the mix offer various options in terms of performance and color. The wide range of available materials can make selecting the right dry-shake concrete hardener powder confusing. The type of aggregate has a significant impact on the final appearance and performance of the floor, but there is no definitive international standard specifying the type or quantity of aggregate.
The decision to choose a particular type of dry-shake hardener depends on several factors, including the application conditions, durability, aesthetics, and cost. For industrial applications, the best guideline for making a determination is by comparing the abrasion resistance properties of the products.
Abrasion resistance is the ability of a surface to withstand abrasion caused by rolling, sliding, cutting, and to some extent, impact. Wear processes are complex and can involve a combination of various actions by different objects in many environments. Examples include a truck tire rolling on a road, dragging a metal or wooden pallet across a surface, human foot traffic, and the impact of tools.
The abrasion resistance of a floor depends on the composition of its materials and the method of its installation. The hardness and strength of the material depend on the hardness of the aggregate and its composition. The hardness of minerals is measured using the Mohs scale, where 10 is the highest value, represented by diamond, and 1 is the lowest value, indicating the softness of talc.
Heavy industrial traffic and operational conditions create more than just wear and tear. Impact, temperature fluctuations, compressive forces, and vibrations from various sources can exert significant stress. The overall hardness and ability of the floor to withstand common stresses have a notable impact on the floor’s lifespan.
Dry-Shake Hardened are applied as a dry powder directly onto the surface of fresh concrete. This application can be done manually or mechanically. Manual application is typically carried out after the initial setting and leveling of the concrete. However, in flooring without a hardener, the application of a power trowel is usually done immediately after concrete placement and before the initial setting of the concrete.
The final thickness of the sprayed-on hardening coating should be between 2 and 3 millimeters. The consumption rate required to achieve this thickness depends on the specific gravity (density) of the dry spray-on hardening powder. The end use of the floor and the type of hardener determine the consumption rate. Additionally, different consumption rates can be considered for different sections of a floor based on the specific applications of those sections.
A consumption rate of 5 kilograms per square meter is ideal when using floor finishing machines like a power trowel. A lower consumption rate is not recommended as the aggregate may sink into the soft concrete surface, and there may be no trace of the hardening powder left. The typical consumption rate for manual application is 4 to 5 kilograms per square meter. Higher consumption rates (up to 7 kilograms per square meter) may also be necessary, but this depends on site conditions, concrete mix, and the amount of water in the concrete. For manual application with higher consumption rates, it is best to apply the material in two stages.
| User type | Dosage |
|---|---|
| Human and light traffic | 3 kg per square meter |
| Semi-heavy traffic | 5 kg per square meter |
| heavy traffic | 7 kg per square meter |
Certain environmental conditions and concrete mixtures with low water-cement ratios (w/c) can make the placement of moderate to large volumes very difficult and should be carefully considered during the planning stages. The w/c ratio of the concrete mixture should be at least 0.50 to ensure sufficient water for the hydration of the hardening cement. Concrete mixtures for interior floors should not contain entrained air, and the measured entrained air volume should not exceed 3%
Achieving a high-quality floor finish using dry-shake hardener requires meticulous planning, coordination, and control.
The concrete mix must be homogeneous, and the delivery schedule of concrete to the job site should be controlled and continuous. Environmental conditions can affect the surface moisture of the concrete and, consequently, the quality and application of the product. The timing of the final float and power trowel work is crucial. Finally, proper curing of the concrete is essential for the ultimate quality of the floor and the dry-shake hardener.
An experienced concrete flooring contractor who is familiar with the nuances and variations of concrete pouring and who utilizes appropriate equipment plays a pivotal role in the successful execution of a project. Professional contractors employ a quality control system, including a detailed execution plan and supporting documentation. The report should include information about timelines, consumption rates, and events that occur during the project.
Dry-shake hardeners provide a cost-effective and durable coating for industrial concrete floors. As with all construction products, proper installation and application are crucial for maximizing the overall quality of the flooring. Selecting the best products and contractors for installation and application results in a floor that performs optimally and, in the long run, leads to easy maintenance and reduced costs.
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