Self-leveling preparation and finishing mortars - XTREMFLOOR®

The self-leveling 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-leveling 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-leveling 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-leveling mortars are for indoor use, there are some mortars suitable for being outdoors. Either way, 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-leveling mortar is mainly used to level those floors that are deteriorated or have irregularities to, then, 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 installation of radiant floors later.

- Sports tracks and other areas: self-leveling mortar is one of the most efficient solutions for creating sports court pavements such as football, basketball or tennis.

- Repair and renovation of stairs: Uneven steps? Self-leveling mortar is an excellent option to solve it and improve people's safety.

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

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

The self-leveling mortar is a product that enjoys countless advantages such as excellent adhesion and leveling capacity. Likewise, it is a very hard mortar because it does not crack or crack and takes very little time to harden. At 3 or 4 hours, as a general rule, it can be stepped 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-leveling mortar a highly demanded system.

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

1. Self-leveling: the self-leveling mortar is specifically formulated so that when poured on 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 must be made in this sense to achieve good leveling.

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

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

4. Time saving and efficiency: self-leveling mortar translates into time and labor savings 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 carried out to prepare and apply a self-leveling 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-leveling 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 liters 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-leveling 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-leveling 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-leveling 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-leveling 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-leveling 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-leveling mortars in thin layer and, on the other hand, self-leveling mortars in thick layer. In this sense, the thickness depends on what type of final product is ultimately used. At Topciment® we have several types of layer thickness: from 1 to 10 millimeters (XTREMFLOOR® Level Concrete) and from 5 to 20 millimeters (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-leveling compounds are suitable for outdoor use; in fact, they are usually used indoors. However, there are some special self-leveling compounds that are optimal for outdoor applications. The mortars from the XTREMFLOOR® range can only be used indoors.

The resistance of self-leveling 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 strength or another.

Taking this into account, the compressive strength of the self-leveling 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 must be differentiated. Firstly, the useful life of the self-leveling mortar from its manufacture, which is usually around 9 months as is the case of our XTREMFLOOR® system. And, secondly, the workability time it has once the mortar has been kneaded.

In this regard, the lifespan of the self-leveling 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. In the specific case of XTREMFLOOR® the workability time at 20ºC is 20 minutes.

Both options are correct. Self-leveling 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-leveling 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-leveling 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 meter. In general terms, the performance of a self-leveling 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-leveling mortar would be needed.

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

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

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

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

- Self-leveling cement mortars.

- Self-leveling mortars of calcium sulfate.

- Magnesite self-leveling mortars.

- Self-leveling mortars of asphaltic putty.

- Self-leveling synthetic resin mortars.

According to the thickness of the layers, we distinguish:

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

- Thick layer self-leveling 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 recognized in the ISO 9001:2015 certificate that we have treasured for years.

For all these reasons, if you want to buy quality self-leveling 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 we will make you a personalized budget at no cost.

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