VARIOPLAN-HD SYSTEM. Benfer. Rev. 02/ Cement-based abrasion resistant continuous floor

Transcription

1 Rev. 02/ Company with quality management system certified by DNV GL ISO 9001 VARIOPLAN-HD SYSTEM Cement-based abrasion resistant continuous floor For the laying of continuous floors For exterior and interior use* For quick laying of floors, rapidly ready for traffic Wear and abrasion resistant Low slipperiness** Available in various colours and finishes Vapour permeable UV and ageing resistant Frost-proof and salt resistant Thickness 6-30 mm Easy to apply, even with pump machine*** EN CT-C40-F10-AR 0.5 *see warning number 12 ** see Technical Data to page 10 *** ***as long as you follow all the informations included in this document CONTRACT ITEM SPECIFICATIONS Laying of exterior and interior cement-based continuous floors resistant to abrasion with antislip classification (according to DIN 51130:2014) equal to R 10, for layers 6-30 mm thick through use of the complete VARIOPLAN-HD system by Schomburg S.r.l. Surfaces must be clean, dry, strong, able to withstand weight, free of grease, oils and paints, and should be treated with abrasion, sandblasting, shot peening, milling or scarification before use of suitable primers, such as STARPRIM, REOPRIM or REOBASE by Schomburg S.r.l. Floor thickness will be laid with abrasion resistant self-levelling cement mortar, such as VARIOPLAN-HD by Schomburg S.r.l. and the surface will be protected with a specific polyurethane finish product such as REOTOP-PU by Schomburg S.r.l., to reduce absorption and improve the abrasion resistance of the surface. It is advisable to spread an even layer of metallic wax over the entire surface of the floor in order to facilitate regular cleaning and maintenance. AREAS OF APPLICATION VARIOPLAN-HD is a coating system for abrasion resistant continuous floors, applicable on screeds, concrete, and on top of old tiles. It is installed in shops, offices, homes, garages, and basements, which require a smooth continuous, wear-resistant surface that is aesthetically different from that obtainable with other more common systems (tiles, PVC, resins etc.). Page 1 of 10

2 COLOURS White, Manhattan Grey, Grey 7035, Grey 7042 SYSTEM COMPOSITION STARPRIM Primer for absorbent and non-absorbent substrates. Composed of special dispersion-based styrene butadiene polymers designed to ensure perfect adhesion on a wide variety of absorbent and non-absorbent surfaces. or REOPRIM Two-component epoxy primer with quartz or REOBASE Moisture blocking two-component epoxy primer with quartz VARIOPLAN-HD Abrasion resistant self-levelling cement mortar REOTOP-PU REOTOP-PU Two-component wear resistant aliphatic polyurethane finish Page 2 of 10

3 BEFORE STARTING System laying provides that material be distributed rapidly over the surface as much as possible and seamlessly. To this end for sites smaller than 30 m², it is advisable that laying be carried out by a team of at least three people who can simultaneously mix, distribute and de-aerate the product. Working in this way, it will be easier to obtain a level floor properly without obvious differences in colour. Bigger dimensions sites requires a team consisting of at least 5 persons, organized as follow: 2 persons mixing VARIOPLAN-HD 1 person moving and pouring the mixed VARIOPLAN-HD 1 person distributing the product with the metal rake 1 person de-aerating the product with the spiked roller A team of this kind can apply up to 300 m² per day of VARIOPLAN-HD. Working in this way it will be easier to obtain a properly levelled floor without evident colour inhomogeneity. In addition, it is possible to use the special machine which mix and pump VARIOPLAN-HD simultaneously, and with four operators allows the laying of app. 100 m² per hour, with consistent savings. Our technical office is available to give all the information on this matter. Acclimatize at a temperature within 15 C and 25 C the system components almost 24 hours before the use, including the mixing water, in case its temperature at the exit from the tip is out of the range. Consider that for a small site of just 30 m² app. 80 litres of water are necessary. ENVIROMENTAL CONDITIONS During the application of the system the temperature must be between 10 C and 35 C. Protect the surfaces against direct sunlight, air draft or strong wind and high relative humidity. Make sure that dew drops there are never on substrates to prevent adhesion problems. SUBSTRATE CONDITION AND PREPARATION The surface must be clean, dry, strong, able to withstand weight, free of grease, oils and paints. All substances that could impair adhesion must be removed. Remove highly contaminated areas mechanically and oil and wax residue. Fill voids and holes with TRIOTECH-50 or BENFERCURE-VARIO. Seal cracks with epoxy resin REOREP or with REOPRIM mixed with REOFIBRE. The tensile strength of the substrate must never be below the average of 1.5 N/mm² (the lowest single value must be no less than 1.0 N/mm²). Prepare the substrate with suitable methods such as for example sandblasting and shot peening, milling or scarification to obtain a surface that provides good mechanical bonding to the system. Traditional non-smooth cement based screeds and those prepared with SOLIDONE PRONTO require only light surface abrasion to detach loose parts. Anhydrite-based screeds must be dry (relative residual moisture less than 0.5% or 0.3% for heated screeds) and the surface must be abraded until the complete elimination of the weak surface film. Heated screeds must be dry and operations can begin only after start-up, full operation and shut-down of the heating system in accordance with the instructions of screed and heating system suppliers and the requirements of relevant certificates. Existing ceramic or natural stone flooring must be tightly secured to the substrate and carefully abraded in order to roughen the surface. All reactive resin finishes with the ability to sustain weight and properly attached to the substrate can be covered with VARIOPLAN-HD only after having been sanded. If the substrate is damaged by de-iced salts, eliminate the substrate until you find a noncontaminated area, using appropriate methods such as scarifying or chiselling. Carefully aspirate the substrate until dust is completely eliminated. Then apply insulating self-adhesive tape BS-SK50 to the areas adjacent to walls and in the vicinity of other breaks in the floor to prevent stress in materials and to prevent the self levelling compound from penetrating in the space between the substrate and walls. Page 3 of 10

4 CHOICE OF PRIMER Use the STARPRIM Primer only in the presence of all the following conditions: Cement-based support or old tiles and natural stones Finished system thickness < 20 mm Interior environment Floor spans < 6 metres Intended for residential or light commercial use Use REOPRIM if even one of the following conditions occur: Anhydrite supports or pre-existing reactive resins Finished system thickness > 20 mm Floor spans > 6 metres Intended for high traffic commercial use Garages or load bearing rooms. Always use REOBASE in any case where there is concern of moisture rising or in the presence of residual moisture of the cement-based screed exceeding 4% (but less than 6%). STARPRIM primer application Use STARPRIM only on substrates and in the conditions listed above. Mix product well before use. Apply a quite generous first coat of Primer (approximately 500 g/m²) to fill all the small cavities of the substrate. We recommend using a rubber rake or flat metal spatula, pressing down the product several times. Wait until the first coat is dry to the touch before applying a second coat (consumption approximately 150 g/m²), using a mohair type roller with hair length 4 mm. REOPRIM and REOBASE primer application Both products are composed of two components, A (resin) and B (hardener), present in the correct mixture ratio. Pour component B in component A. Make sure that the hardener comes out completely from the container. Components should be mixed with a suitable mixer at about 300 rpm. It is important to also mix the material on the sides and bottom of the container to ensure that the hardener is spread evenly. Mix until the mixture is even. The time required for even mixing is approximately 3 minutes. Minimum temperature of product during mixing must be 15 C. Do not use material directly from the packaging. We in fact recommend pouring the mixed product into another container and thoroughly mixing again. Apply a single coat of Primer (approximately 600 g/m²) to fill all the small cavities of the substrate. We recommend using a rubber rake or flat metal spatula, pressing down the product several times. As soon as primer has been spread, sprinkle the surface with quartz sand of grain size mm (consumption approximately 1 kg/ m²). Once the Primer has hardened (approximately 16 hours), carefully remove excess quartz sand before applying coating. Page 4 of 10

5 VARIOPLAN-HD APPLICATION After at least 16 hours from primer application, mix 25 kg of VARIOPLAN- HD with 6.25 litres of clean water at room temperature. Pour 2/3 of the water required and then 25 kg of VARIOPLAN-HD in a clean bucket. Stir until you obtain a mixture without lumps and add the remaining 1/3 of water. Scrape the container walls with a spatula to evenly mix all the material (no streaks). We then recommend pouring the whole mixture into another bucket, filtering it with 1 mm side square mesh netting and mixing once again. The minimum recommended mixing time is approximately 3 minutes. We recommend using a mixer at speed rpm. Double helix electrical mixers have proven the most effective for obtaining a homogeneous mixture. Product unfiltered > Following this procedure minimises the possibility of having any small lumps of material in the mixture which can cause defects on the surface. Pour VARIOPLAN-HD on the substrate prepared with Primer and spread it uniformly within the pot life using a suitable tool, for example a metal rake with adjustable spacer teeth. Fasten the spacers so as to obtain a homogeneous levelling thickness of at least 5/6 mm. It is possible to fasten level indicators while the surface is not yet hardened to obtain the desired thickness, which can be obtained in a single application. The fresh mortar must be de-aerated with a toothed roller, at the same time favouring levelling. Surface aesthetics and levelling are significantly improved by using this method. At the end of laying, protect VARIOPLAN-HD setting from too rapid water loss due to high room temperature, direct sunlight and drafts. After waiting at least 24 hours, remove residual dust that has formed on VARIOPLAN-HD, cleaning the surface first with soft felt and then with careful aspiration. For this operation,and for the following, we recommend not wearing footwear that could leave traces which, when covered with REOTOP- PU, cannot be removed. It is beneficial to use soft wool socks over footwear. Page 5 of 10

6 REOTOP-PU APPLICATION The product is composed of two components, A (resin) and B (hardener), present in the correct mixture ratio. Pour component B in component A. Make sure that the hardener comes out completely from the container. Components should be mixed with a suitable mixer at about 300 rpm. It is important to also mix the material on the sides and bottom of the container to ensure that the hardener is spread evenly. Add 10% water to the product during mixing. Mix until the mixture is even. The time required for even mixing is approximately 3 minutes. Minimum temperature of the product during mixing must be 15 C. Do not use material directly from the packaging. We in fact recommend pouring the mixed product into another container and thoroughly mixing again. Apply the finish using a mohair type roller with hair length 4 mm in at least two crossed coats at a distance of 6 hours from each other. Prepare the instrument by rolling the scotch tape around the roller. When you remove it, it will detach bristles in excess. The product must be applied so as not to leave too large a thickness on the surface. Approximately 60 g/m² for each coat is considered correct application. Protect finished and sealed coating over the first 24 hours from the elements, such as strong sunlight, wind, rain etc. and damage caused by excessive mechanical load. WAX APPLICATION 24 hours after surface sealing with REOTOP-PU, it is advisable to spread an even layer of metallic wax over the entire surface of the floor using a special wax applicator tool or, alternatively, a soft rubber spatula to facilitate regular cleaning and maintenance. To obtain an optimal level of protection and ease of cleaning, spread the product in two crossed coats for a consumption of approximately 50 g/m² per each coat. Wait for the first coat to fully dry before applying the second coat. Page 6 of 10

7 WORK TOOLS We recommend using the following tools to optimise floor laying: Monobrush machine or sandblasting machine for bottom preparation. The monobrush machine can also be used to facilitate removal of excess quartz sand from the epoxy primer and to clean the surface of VARIOPLAN-HD of accumulated dust residue. Rubber rake with handle is suitable for primer application. It in fact permits the user to work standing up, distributing the optimal quantity of material (approximately g/m²). Metal rake with adjustable spacer teeth for easy spreading of VARIOPLAN-HD self-levelling cement mortar and to check thickness uniformity at any time. The adjustable spacer teeth allow users to create different thicknesses using a single tool. Toothed roller The fresh mortar must be de-aerated with a toothed roller, at the same time favouring levelling. Surface aesthetics and levelling are significantly improved by using this method. Thinset shoes with steel bottom. Wear it on normal shoes to walk on VARIOPLAN-HD during the rolling of the product. Mohair type roller used to apply the second coat of STARPRIM primer and to distribute REOTOP-PU polyurethane coating on the finished surface. A special type of roller with short hair allows the user to lay the finish and not accumulate a quantity of product exceeding 60 g/m² per each coat. Wax applicator for the application of two coats of wax for maximum surface protection VARIOPLAN-HD mixer / pump machine: lightweight and easy to use machine for mixing and pumping the VARIOPLAN-HD. It permits to mix properly and to pump the product at the same time up to 15 metres far away. With this machine and 4/5 persons it is possible to apply 100 m² / hour saving a lot of money and efforts. Particularly indicated for sites bigger than m². Page 7 of 10

8 Company with quality management system certified by DNV GL ISO 9001 > FULL SERVICE CONDITIONS The floor can be used by pedestrian transit after 24 hours by the end of installation. After at least 7 days the area can be trafficked with car and mechanical and lightweight forklift machines. > Typical Shades of VARIOPLAN-HD Page 8 of 10

9 WARNINGS 1. The products of the system, especially REOPRIM, REOBASE e REOTOP-PU, must be stored at a temperature between 15 C and 25 C in the 24 hours preceding their use. 2. Existing substrate joints must be included in coating and slippage of the product inside must be prevented using appropriate methods. It is however necessary to create fraction joints at least every 60 m². In the case of heated floors, painted backgrounds must be reduced to m². Where VARIOPLAN-HD application is carried out in the civil sector (apartments, shops, etc.), in any case provide also for room dimensions lower than those previously described for expansion joints near door thresholds or where a substantial volumetric change of the rooms to be coated exists. It is also possible to mark the position of the joint on walls, fill it with self-levelling compound during laying and restore the joint, cutting it with a flexible grinding wheel the next day. 3. Seal joints with DEKOFLEX-PU, 1-component polyurethane joint sealing adhesive for sealing expansion and fraction joints. 4. If necessary, spread another layer of VARIOPLAN-HD, apply a coat of intermediate primer. 5. During machine application, continuously verify the slump value. Check using a Vicat ring in accordance with DIN 1164, where the internal top diameter is 65 mm and the bottom diameter is 75 mm. Determining the slump value is carried out for example on a glass surface and must be approximately 35 cm. 6. With thickness 20 mm, VARIOPLAN-HD can be walked on after approximately 24 hours. After 7 days, the area can be travelled over by lightweight (max 1000 kg), forklifts. In the case of polyamide-wheel vehicle traffic, there is a risk of surface damage and therefore this situation must be avoided. 7. Protect finished and sealed coating over the first 24 hours from the elements, such as strong sunlight, wind, rain etc. and damage caused by excessive mechanical load. 8. Protects areas that are not to be treated from the effects of VARIOPLAN-HD. 9. VARIOPLAN-HD is suitable for sealing small static shrinkage cracks or hairline cracks up to 0.1 mm wide. It is not suitable for sealing larger or dynamic cracks. 10.Hardened coating has a slightly uneven appearance (whitish shading) due to the setting, to irregular absorption of the substrate, to high moisture in the environment, to premature exposure to water, and as a result of the slight natural colour variability of the raw material. These are properties of the product and are absolutely not be considered defects. 11.Coating must not be exposed to water during setting. Penetrating moisture can cause detachment in the presence of frost. 12.Consider the following warnings for outdoor system use: the system does not allow the laying of sloping floors for the disposal of rainwater. The presence of water on the floor increases surface slipperiness. Please consider the value of slipperiness of the system in the design. Page 9 of 10

10 TECHNICAL DATA: Colours: White, Manhattan Grey, Grey 7035, Grey 7042 Minimum thickness: 6 mm Maximum thickness: 30 mm STARPRIM consumption: approx kg/ m² REOPRIM consumption: approx kg/ m² REOBASE consumption: approx kg/ m² VARIOPOLAN-HD consumption: approx kg/m²/mm thick REOTOP-PU consumption: approx kg/ m² WAX consumption: approx kg/ m² Appl./surf.temperature: From +10 C to +35 C Traffic after: 24 hours Heavy traffic after: 7 days Tensile adhesion strength: > 1.5 N / mm² after 28 days Flexural strength: approx. 10 N/mm² after 28 days Compressive strength: approx. 40 N/mm² after 28 days Classification: EN CT- C40 F10 AR 0.5 Shore D hardness after 12 hrs: approx (in compliance with DIN 53505) Water vapour resistance coefficient μ: approx. 200 Full service conditions: after approx. 7 days Slipperiness (according to DIN :2014): Average angle of slipperiness:14.3 Classification: R 10 Slipperiness (according to D.M. 236/89 Rif. B.C.R.): Average friction coefficient on dry surface (μ): 0.36 Average friction coefficient on wet surface (μ):0.50 Slipperiness (according to DIN 51097:1992): Average angle of slipperiness 28,4 Classification: C Storage: dry for 12 months in the original unopened packaging. Use opened packaging promptly. For further information on VARIOPLAN-HD system components, please refer to the latest data sheets and safety data sheets of individual products and watch the application cycle video at Page 10 of 10 FR