TYPICAL TECHNOLOGICAL CARD
Installation of cement-sand floor screed with fiber reinforcement mechanized way
1 AREA OF USE
1 AREA OF USE
1.1. The technological map has been developed for the installation of cement-sand screeds from a rigid semi-dry mortar, with the addition of polypropylene synthetic fiber (construction micro-reinforcing fiber - VSM), carried out by mechanization, intended to level the surfaces of the underlying floor element or to give the floor a given slope.
The thickness, strength of the screed and material are assigned by the project depending on the type of floor covering, the design of the floors and the purpose of the premises based on the requirements:
SP 29.13330.2011 Floors. Updated version of SNiP 2.03.13-88;
Floors. Set of rules (in development of SNiP 2.03.13-88 “Floors” and SNiP 3.04.01-87 “Insulating and finishing coatings”);
MDS 31-6.2000 "Recommendations for the installation of floors", regulating the sequence of operations for preparing and installing cement-sand hard semi-dry mixtures (mortars) using polypropylene synthetic fiber, - screeding and quality control of the work performed (Fig. 1).
Fig.1. Fiber screed device
When developing this technological map, the requirements for the quality of the materials used were also taken into account:
- GOST 8736-93 Sand for construction work. Specifications (as amended);
- GOST 25328-82 Cement for mortars. Specifications ;
- GOST 7473-2010 Concrete mixtures. Specifications ;
- Amendment No. 1 GOST 28013-98 Construction mortars. General technical conditions.
The developed technology for the production and installation of screeds using fiber fiber, modern Russian and German equipment is used in the most various industries activities:
- Housing and civil complexes;
- In industrial, civil and public buildings(Fig. 2);
Fig.2. Installation of floor screeds in industrial, civil and public buildings
In production and industrial workshops;
- When arranging storage facilities;
- In garages and auto repair shops;
- In trading floors and exhibition complexes;
- In multi-storey parking lots;
- In aircraft hangars and cargo terminals;
- IN office premises, basements and roofs.
Technological stages of installing a floor screed using a mechanized method with fiber reinforcement(Fig.3)
The necessary measurements are taken and a topographic map of the room is drawn up. The purpose is to measure the area and thickness of the layer. From a given reference point (options are possible), deviations from the horizon to the existing coating are recorded using a laser level. Based on recording deviations and their further calculation at many points, the future thickness of the screed is determined;
- the base is prepared - the surface is freed from foreign objects and debris;
- equipment - a pneumatic supercharger - is located in the immediate vicinity of the work site (on the street). It is a self-contained, diesel-powered semi-trailer unit;
- mortar hoses, through which the mixture prepared in the pneumatic blower is subsequently transferred to the work site, are mounted from the equipment to the premises;
- the necessary materials are placed in the immediate vicinity of the equipment - sand, cement, fiberglass, plasticizer, water (constantly replenished container);
- the surface in the room is covered with a technical film, a damper tape is installed around the perimeter of the room and in places adjacent to vertical surfaces;
- in certain proportions, the material is supplied to the mixing chamber of the pneumatic blower, mixed and portionedly supplied to the work site (possibility of supplying ready solution to a height of up to the 30th floor);
- the mixture is taken in using a special damper connected to the hoses high pressure, pre-planned, compacted;
- from a given horizon line along special technology beacons are formed from the finished mortar for later laying the ready-made hard (semi-dry) mortar at an equal distance from the given horizon line;
- with the help of special smoothing slats (rules), the surface is formed according to previously made beacons;
- the surface is rubbed and additionally compacted with a surface grinder;
- expansion joints are cut;
- the surface is covered with plastic film.
Fig.3. Technological stages of screed installation
2. GENERAL PROVISIONS
ORGANIZATION OF THE CONSTRUCTION PROCESS FOR INSTALLING A FLOOR SCREED
2.1. A screed is a monolithic or prefabricated layer of relatively durable material in multilayer structures of floors and roofings of buildings. Designed to absorb, distribute and transmit loads (for example, on roofs - snow cover, on floors - the presence of people, cargo, equipment), to level the underlying layer or give the covering layer of roofing and floor structures a given slope, as well as to lay the finishing layer on them coverage, movement of equipment and people on it.
2.2. Work on installing screeds using fiber fiber (construction micro-reinforcing fiber - VSM) must be carried out in accordance with the requirements of SNiP after completion of construction and installation work, during the production of which the screed may be damaged.
2.3. The screed can be installed at an air temperature at floor level and the temperature of the underlying layer is not lower than 5°C; the temperature must be maintained for the entire duration of the work and until the screed acquires a strength of at least 50% of the design strength.
2.4. A screed made of rigid semi-dry mortar, performed using a mechanized method, must be laid once to the design height.
2.5. In order to prevent the transfer of deformations to the floor screed from the building structures along the walls, around columns and foundations, insulation joints are installed by laying insulating material
(damper tapes made of foamed polyethylene, isolon, isokom) to the entire height of the screed immediately before laying the mortar.
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What is a domain:
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Routing devices for semi-dry DSP floor screeds
Technological map developed for the device cement screed from a semi-dry solution, carried out mechanically using equipment for preparing and supplying the solution.
This technological map has been compiled on the basis of the requirements of SNiP 3.04.01-87 “Insulating and finishing coatings", SNiP 2.03.13-88 "Floors", MDS 31-6.2000 "Recommendations for the installation of floors" and regulates the sequence of operations for preparing cement-sand semi-dry mixtures (mortars) with reinforcing polypropylene fiber, screeding and quality control of work performed. This technological the card takes into account the quality requirements for the materials used, namely: GOST 8736-93. " technical specifications"; GOST 25328-82. ". Technical conditions"; GOST 7473-94. “Concrete mixtures. Technical conditions"; GOST 28013-89. “Building mortars General technical conditions”; GOST 26633-91.
Technological map for installing semi-dry floor screed.
1. Instructions for the preparation of cement-sand semi-dry mixtures with polypropylene reinforcing fiber using equipment for mixing and pneumatic feeding through hoses.
2.Technical requirements. Device technology.
3. Device positions, technical control, acceptance.
1. Instructions for the preparation of cement-sand semi-dry mixtures with polypropylene reinforcing fiber using equipment for mixing and pneumatic feeding through hoses.
When making cement-sand underlying layers () using the semi-dry screed method, the following requirements for the preparation of solutions must be observed:
The ratio of sand volume to cement volume is 3: 1; The Turbosol M-250 equipment has a mixing hopper volume based on the actual volume of the mixture of 250 liters. Minimal amount cement per bunker loading should not be less than 50 kg (1 standard bag).
The water-cement ratio is in the range of 0.35-0.50, which corresponds to 17-24 liters of water per bunker load. Data for natural humidity.
Loading of sand, cement and water is carried out into a working mixing hopper in two stages, namely:
First, a volume of sand (about 75 kg) and the entire bag of cement (50 kg) are loaded. Next, add a bucket of water (10-12 liters);
Next, the operating bunker is finally loaded with sand (about 100 kg) and required quantity water (7-12 liters). The full loaded mass is mixed for at least 2 minutes. The total operating time of the mixing hopper, taking into account the loading time, is from 4 to 7 minutes.
The consumption of polypropylene fiber used for volumetric reinforcement is about 120-150 grams per full load of the hopper or per batch of solution. Based on 1 m3 of prepared solution, the consumption of polypropylene fiber is 700 grams. Polypropylene fiber is added with each portion of water, i.e. for 1 bucket of water about 60 - 70 grams.
2.Technical requirements. Device technology, brief instructions.
The supply of the prepared cement-sand semi-dry mixture (mortar) to the place where the screeds are installed is carried out by the pneumatic transport unit of the Turbosol M-250 equipment and should not exceed 3-5 minutes. In particularly difficult supply conditions, for example: hose lengths of more than 150 m and supply heights of more than 80 m, the supply time can reach 7-10 minutes. When negative temperature outside air down to minus 10 °C, the preparation and supply of a cement-sand semi-dry mixture (solution) is permitted with the obligatory installation of a “warmhouse” above the installation site of the Turbosol M-250 equipment. With more low temperatures Preparation and supply of semi-dry cement-sand mixture (mortar) is not recommended.
Allowed at a temperature of laid materials not lower than 5 0C and a positive air temperature in the room, measured in the cold season near the door and window openings at a height of 0.5 m from the floor level.
Cement-sand screed made from semi-dry mixtures should not have direct contact with the enclosing structures of the premises. This requires laying soundproofing (damping) tapes made of polyethylene foam 4-8 mm thick over the entire height of the screed along the entire perimeter of the junction with walls, partitions, and other structures.
The installation of screed with a semi-dry mixture should be carried out immediately to the calculated thickness, because it is the basis for finishing flooring.
The minimum total thickness of the cement-sand screed is at least 40 mm.
The local minimum possible thickness of the cement-sand screed is 30 mm.
After supplying the cement-sand semi-dry mixture (mortar) to the work site, the mixture is evenly distributed in areas limited by compacted mortar beacons installed along the level. The cement-sand semi-dry mixture (mortar) is leveled with a tool called a “rule”, which is moved with double-sided support onto these beacons.
Grinding the surface of the underlying layers (screeds) should be done with a machine equipped with a leveling disc. Surface grinding should begin immediately after leveling the mortar at a given level and should be completed before the mortar begins to set (about 1 hour from the moment of application).
In premises with an area of more than 45 sq.m. During the work process, it is recommended to draw up a map of the sequence of filling areas, divided into areas of up to 10 - 15 sq.m. Grout already finished site premises should begin simultaneously with leveling the next section. In this case, the end surfaces of individual sections of the room are not processed, and their junctions with a 2-3 mm gap form the required expansion joint.
The execution of expansion joints of the slab (screed), required for rooms with a size in one dimension of more than 6 m, is recommended in two ways, namely:
Expansion joints 5-7 mm wide, made directly during the screed grinding process, are technologically produced using the mechanical cleaning using a trowel to remove crumbled mixture residues from the adjacent areas to the entire depth of the screed. Next, in the process of smoothing the adjacent area, a small amount of semi-dry mixture is poured on top of the seam and the seam and areas of the adjacent areas are smoothed. This achieves the result of a visually uniform surface with an organized expansion joint within the entire thickness of the screed.
3. Device positions, technical control, acceptance.
| Technological operations production of works and requirements for them | Control (method, volume, type of registration) |
| Preparation of cement-sand semi-dry mixtures (solutions) with reinforcing polypropylene fiber | Acceptance of floors, the elements of which are made of materials that harden after installation, is allowed no earlier than they reach the design strength; the strength of these materials must be determined by testing control samples in an amount of at least three for every 500 m 2 floor layer. In the absence of control samples, a compression test must be carried out on at least three cubes with an undamaged structure and an edge size of at least 25 mm, taken from the floor layer. |
| Laying insulating (damping) tapes made of foamed polyethylene with a width of 8 to 15 mm over the entire thickness of the screed along the entire perimeter of the junction with walls, partitions, other structures, as well as in doorways. | Visual, all junction points, work log. |
| The nominal thickness of the cement-sand coating above the heat pipe is 30 mm. In cases of installation of an installation field in conditions of maximum permissible curvature of the base, the thickness of the cement-sand coating above the heat pipe is not allowed to be less than 15 mm in certain places of the heat plate | Measuring, at least three measurements for every 50-70 m 2 of screed surface or in one room of a smaller area. |
| Deviations of the element plane from the horizontal or a given slope - 0.2 of the corresponding room size, no more than 50 mm | The horizontality of the surface of each floor element is checked in all directions of the levels and with a 2 m long control strip, and if there is a slope, with a control template strip with a level |
| Sanding the surface of the screeds should be done using a machine equipped with a leveling disc. Surface grinding should begin immediately after leveling the mortar at a given level and should be completed before the mortar begins to set (about 3 hours from the moment of application). | Measuring, at least five measurements evenly for every 50-70 m 2 of screed surface or in one room of a smaller area. |
| Execution expansion joints thermal plate (screed) required for rooms with a size in one dimension of more than 6 m. | Technical, all seams. |
Technological map for the installation of semi-dry cement-sand screed
1 AREA OF USE
1.1 The technological map has been developed for the installation of cement-sand semi-dry screeds. SNiP 2.03.13-88 “Floors”. MDS 31-6.2000 “Recommendations for flooring” regulating the sequence of operations for the preparation and installation of cement - sandy hard semi-dry mixtures (mortars) using polypropylene synthetic fiber - installation of screed and quality control of the work performed. When developing this technological map, the requirements for the quality of the materials used were also taken into account: GOST 8736-93 “Sand for construction work. Technical specifications. GOST 25328-82 “Cement for mortars. Technical conditions. GOST 7473-94 “Concrete mixtures. Technical conditions. GOST 28013-89 “Building mortars. General technical conditions".
The developed technology for the production and installation of fiber-reinforced floor screeds using modern German equipment is used in a wide variety of industries: Housing and civil complexes In industrial, civil and public buildings. In production and industrial workshops. When arranging warehouse premises. In garages and auto repair shops. In trading floors and exhibition complexes. In multi-storey parking lots. In aircraft hangars and cargo terminals. In office premises, basements and roofs
2. ORGANIZATION OF THE CONSTRUCTION PROCESS FOR INSTALLING A FLOOR SCREED
2.1. A screed is a monolithic or prefabricated layer of relatively durable material in multi-layer structures of floors and roofings of buildings. It is intended for the perception, distribution and transmission of loads, for example: (on roofs - snow cover, on floors - the presence of people, cargo, equipment), for leveling the underlying layer or giving the covering layer of roofing and floor structures a given slope, as well as for flooring on them of the finishing coating, the movement of equipment and people on it.
2.2. Work on installing a screed using construction fiber must be carried out in accordance with the requirements of SNiP, after completion of construction and installation work, during which the screed may be damaged.
2.3. The screed can be installed at an air temperature at floor level and the temperature of the underlying layer is not lower than 5 0C; the temperature must be maintained for the entire duration of the work and until the screed acquires a strength of at least 50% of the design strength.
2.4. A screed made from a rigid semi-dry mortar, made using a mechanized method, must be laid once to the calculated height.
2.5. In order to prevent the transfer of deformations to the floor screed from the building structures along the walls, around columns and foundations, insulation joints are installed by laying insulating material (damper tapes made of foamed polyethylene, Izolon, Izokom) to the entire height of the screed immediately before laying the mortar.
2.6. To prevent random cracking of the screed during hardening and strength gain, it is necessary to cut shrinkage joints. Shrinkage seams must be cut along the axes of the columns and connected to the corners of the seams running along the perimeter of the columns. The floor map formed by shrinkage joints is cut into squares whenever possible. The length of the card should not exceed the width by more than 1.5 times. A generally accepted rule is that the smaller the card, the less likely it is to randomly crack.
2.7. When installing screeds from rigid semi-dry mortar, taking into account their design features, on the object you should perform:
1. Preparatory work; ensuring access roads for freight transport to the production site; determining the location of equipment installation and storage; building materials for the production and supply of the mortar mixture, providing an access point to power supply, providing the necessary lighting for the production site, supplying process water to the equipment installation site2. Technological operations; cleaning the surface of the underlying layer making marks of the clean floor installing insulating material along the entire height of the screed along the perimeter of the walls, around columns and foundations preparing cement-sand mortar supplying the mortar to the installation site installing beacons laying cement-sand mortar grinding the surface of the screed with trowels cutting expansion joints
3. ORGANIZATION AND TECHNOLOGY FOR PERFORMING WORK ON FLOOR SCREADING
3.1. Cleaning the surface of the underlying layer is carried out before laying the cement-sand mortar. The surface of the base is inspected, thoroughly cleaned of debris and foreign deposits, the horizontalness of the base and the correctness of the slopes are checked, grease stains are removed, if there are cracks in the base, the cracks are widened and filled with a repair compound, and the gaps between the prefabricated slabs are sealed. The base must be clean, strong and free of peeling.
3.2. Making marks. The level of the finished floor is determined by surveyors using laser level. It should be taken into account that the level of the finished floor must be the same in all rooms of the apartment or part of the floor located between adjacent staircases.
3.3. Insulation seams. In order to prevent the transfer of deformations to the floor screed from the building structures along the walls, around columns and foundations, insulation joints are installed by laying insulating material (damper tapes made of foamed polyethylene, Izolon, Izokom) 4-8 mm thick over the entire height of the screed immediately before laying the mortar.
3.4. Preparing the screed. The location for installing the compressor, specialized pneumatic transport equipment for preparing and supplying the mixture, and the storage location for building materials must be specified in the work project or agreed with the Customer. The required area for placing equipment and materials is from 30 to 50 m2; Semi-dry screed is prepared directly at the construction site or at the work site. When preparing the screed using a mechanized method using fiber fiber, certain requirements are met, the ratio of the volume of sand to the volume of cement should be 3:1 under the strict condition that the washed seeded sand corresponds to a fraction with a particle size module of 2-3 mm. Standard pneumatic conveying equipment has a mixing hopper volume of 250 liters, according to the actual volume ready mixture 200 liters. The minimum amount of cement per bunker loading should not be less than 40 kg. The water-cement ratio is in the range of 0.34 - 0.45, which corresponds to 17-24 liters of water per bunker loading. Loading sand, cement and water is carried out in two stages. First stage: - first, ½ volume of sand (about 75 kg) and a 50 kg bag of cement are loaded. Next, 10-12 liters of water and polypropylene fiber are added. Second stage: - the operating bunker is finally loaded with sand of about 100 kg and the required amount of water of about 7-12 liters, as well as fiber. The consumption of polypropylene fiber used is about 120 - 150 grams per full load of the hopper, i.e. for one batch at the rate of 300-500 grams per cubic meter of prepared solution. Fibrin is added with each proportion of water. The full loaded mass is mixed for at least two minutes. The total operating time of the mixing hopper, taking into account the loading time, ranges from 4 to 7 minutes.
3.5. Supply of the solution to the installation site. The prepared cement-sand mortar is brought under pressure, in portions through rubber hoses, directly to the installation site and placed on the base through a solvent extinguisher. In large areas, floor screeding is carried out using cards. The size of the map is determined by the productivity of the working unit, that is, the area of the floor laid in one work shift. The supply time of the prepared solution should not exceed 5 minutes. Depending on the type of equipment, delivery can be carried out at a distance of up to 160 meters horizontally and 100 meters vertically. If it is necessary to deliver the solution over a distance of more than 100 meters, the delivery time can take up to 7-15 minutes. At negative outside air temperatures not exceeding minus 10 0C, preparation and supply of the solution is possible with the obligatory installation of a so-called “warmhouse” at the installation site of the compressor and specialized pneumatic transport equipment.
3.6. Construction of beacons and laying of cement-sand mortar. The installation of beacons is made from freshly prepared mortar with preliminary leveling with a level without installing guides. After supplying the cement-sand semi-dry mixture (mortar) to the work site, the entire volume of the prepared map is filled with the mixture. The mixture is drawn out using a screed rule, which is moved with double-sided support onto these beacons until flat surface. During work, it is necessary to monitor the condition of the exposed beacons. Leveling the surface and installing beacons is carried out simultaneously, which ensures uniform laying and the subsequent complete absence of cracks.
3.7. Grinding the surface of the screed. Surface grinding work must begin immediately after leveling the mortar and be completed before the mortar begins to set within 1.5 - 2 hours from the moment of application. Surface grinding should be done with a trowel equipped with a leveling disc and wearing special shoes - concrete shoes.
3.8. Cutting expansion joints. To prevent random cracking of the screed during hardening and strength gain, it is necessary to cut expansion joints, as a result of which the screed cracks in a given direction.
There are three main types of expansion joints:
- Insulation seams
- Shrink seams
- Construction seams
It is more expedient to cut shrinkage joints in freshly laid mortar with a special cutter after treating the surface of the mortar with a trowel. The seams must be cut along the axes of the columns and connected to the corners of the seams running along the perimeter of the columns. The floor map formed by shrinkage joints is cut into squares whenever possible. The length of the card should not exceed the width by more than 1.5 times. The depth of the seam should be 1/3 of the thickness of the screed. Seams allow you to create straight planes of slack in the screed. Obviously, the smaller the map, the less the likelihood of random cracking. Construction joints are tripled in places where the work of laying the screed of the working link ends for the shift. Construction seams operate on the shrinkage principle and should be aligned whenever possible.
4. Requirements for quality and acceptance of work.
4.1. Acceptance of work on installation of screeds is carried out in accordance with the requirements of SNiP III-B.14-72 “Floors. Rules for production and acceptance of work":
4.2. Cracks, potholes and open seams in screeds are not allowed. Deviation of the thickness of the screeds from the design is allowed only in certain places and should not exceed 10% of the specified thickness
4.3. The surface of the screeds must be at the level of the specified marks
4.4. The surface of the screeds must be horizontal or have a specified slope. Horizontalness is checked using a control rod with a level
4.5. The evenness of the surface of the screeds is checked with a two-meter rod, moved in all directions. The gaps between the screed and the batten should not exceed 2 - 4mm.
4.6. Humidity of screeds when installing linoleum floors, PVC tiles, textile coverings, piece parquet, parquet boards and panels should be no more than 5%.
5. Safety precautions and labor protection
5.1. Before starting work on screeds, responsible person for their production, is obliged to ensure that workers are instructed and provided with the necessary protective clothing and equipment personal protection. When performing work, it is necessary to comply with the safety regulations set out in SNiP III-4-80 “Safety in construction”.
5.2. Special attention you should pay attention to the following: persons at least 18 years of age who have passed a medical examination and have certain qualifications are allowed to service installations and mechanisms, knowledgeable about the device and design features of the equipment that have a certificate for the right to service; in accordance with the “Rules technical operation electrical installations of consumers” installations must have their own grounding center.
5.3. Before starting work, the driver is obliged to: carry out an external inspection of the installation, the condition of the entrance to it; check the serviceability of electrical wiring and grounding; check the alarm system for workplaces.
5.4. During work, the driver is obliged to: start and stop supplying the solution only upon a signal from the workplace; supply the solution only after thoroughly mixing it.
5.5. Persons who have passed the special training and having a certificate for the right to operate. Pressure gauges and safety valves must be sealed. Maintenance of the trowel must be entrusted to a worker familiar with the operating instructions. The machine must be connected to the electrical network by an electrician.
6. Material and technical resources
6.1. Sand for construction work. "Technical conditions". GOST 8736-93
6.2. Cement for mortars. "Technical conditions". GOST 25328-82
6.3. Concrete mixtures. "Technical conditions". GOST 7473-94
6.4. Construction solutions. "General technical conditions". GOST 28013-89 6.5. The need for tools, equipment and fixtures is given in Table 1.
| 1 | 2 | 3 | 4 |
| No. | Equipment for preparing and supplying solutions | units from. PC. | quantity |
| 1 | Mortar pump (pneumatic blower) | PC | 1 |
| 2 | Grouting machine for grouting screed | PC | 1 |
| 3 | Seam cutting machine (seam cutter) | PC | 1 |
| 4 | Industrial vacuum cleaner | PC | 1 |
| 5 | Rake-rule length 3m, 2.5m, 2m, 1.5m, 1m | PC | 5 |
| 6 | Control rack | PC | 1 |
| 7 | Construction level | PC | 2 |
| 8 | Scraper for cleaning the base | PC | 2 |
| 9 | Shovel type LP | PC | 4 |
| 10 | Bucket | PC | 3 |
| 11 | Container for technical water | PC | 2 |
Standard DIN-EN 13813 “Screed material and floor screeds – Screed materials – Properties and requirements”
