The Ultimate Guide to Choosing Self-Leveling Compound Manufacturer

What is a Self-Levelling Compound?

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A levelling compound is a self-levelling liquid used to level out uneven subfloors. It is a fast-drying and easy-to-use product that can be applied over various interior subfloor types, including concrete, tiles, timber and particleboard/plywood. Self-levelling compound is typically used to prepare subfloors for floating floor installation, such as laminate, hybrid, engineered timber, and bamboo flooring or other floor coverings as they require a very flat and even subfloor.

Benefits of levelling compound:

1. Simple & Effective: Easy to use as it lets gravity do the work by pulling the compound into a flat and smooth surface.
2. Rapid Hardening: Most levelling compounds hard set in only 6 &#; 12 hours. This means you can walk and let other trades work whilst it cures, saving you time!
3. Flexible Application: Levelling compound is very versatile and can be used over almost every type of subfloor whether concrete or timber.

How To Determine Whether My Subfloor Needs Levelling

Hard flooring is great, however, their worst enemy is an uneven subfloor. Unlevel subfloors can cause a myriad of problems including bouncing underfoot, creaking noises, and in severe cases &#; damage to the floorboards themselves! Subfloor unevenness can be caused by several factors, such as poor construction, settling, or moisture damage. Luckily, modern technology brings self-levelling concrete into the picture. These are designed to level out the subfloor by coating the surface which will set into a new flat and even subfloor.

A subfloor is considered uneven if it has any variations in height greater than 2 &#; 4 mm over a distance of 2m which isn&#;t a lot if you think about it. Using a spirit level, you can check whether your subfloor is suitable. We recommend a two-metre-long spirit level as it replicates your typical floorboard length. Check the height of subfloor bumps and dips with a ruler as you slide the spirit level across the subfloor. Be sure to rotate and check from different angles.

How Much Unevenness Can My Floating Floor Tolerate?

As a general rule of thumb, most floating floors like laminate boards, engineered timber flooring and bamboo flooring can tolerate around 4mm variance over 2 metres before you begin feeling bouncing underfoot.

Hybrid flooring on the other hand can only tolerate around 2mm variance over 2 metres before the unlevel sections become noticeable.

Note that tiles with large grout lines will require a skim coat of floor levelling compound even if they are flat and even. This is because the click-lock joins can give and break if they are directly above grout lines, especially wider ones.

Can Levelling Compound Be Used On Surfaces Other Than Concrete Slabs?

Yes, they can be used on almost every surface. The application method varies, depending on whether the subfloor is a concrete slab or wooden base. Properly sealed concrete slabs only require a primer before a self-leveller can be poured over, whereas a wood substrate needs waterproofing and sealing as well.

Self-levelling compound cannot be applied over existing floating floors. We highly recommend removing and disposing of any existing floor coverings in advance.

The following subfloors don&#;t always require waterproofing (may require sealing):

• Concrete Slab
• Ceramic, Porcelain and Travertine Tiles
• Aerated Concrete e.g Hebel Flooring

These wood-based subfloors ALWAYS require waterproofing and sealing. This is a non-exhaustive list:

• Solid Timber Flooring
• Wooden Sheets i.e Plywood, Masonite, Particleboard
• Yellow/Blue/Red Tongue Flooring
• Cork Flooring (May be more suitable to remove if there is concrete beneath)

Exceptions which may not be suitable for levelling:

• Magnesite Subfloor &#; This may contain asbestos, hence FloorVenue recommends contacting a professional magnesite removalist company. Especially if it has cracks and bounces underfoot.

How To Use Self-Levelling Compound On Uneven Concrete Slab

Note: Self-levelling compound is not the only way to level a subfloor. If you wish to discover more methods, check out our comprehensive guide on how to deal with an uneven subfloor.

Step 1: Clean & prepare the subfloor

The subfloor must be clean, dry, and free of dust and debris before applying a self-levelling compound. Any cracks or holes in the subfloor should be repaired or sealed using a suitable filler. Be sure to remove any nails or residue glue from previous flooring or carpets that may have been present.

Step 2: Prime the subfloor

Important Note: Wooden subfloors like chipboard, timber or yellow tongue require waterproofing and gap sealing during the priming process. Concrete subfloors only require a primer.

A primer is applied to the subfloor to help the self-levelling compound adhere properly. The primer should be allowed to dry completely before applying the self-levelling compound. Rookies often skip the priming process resulting in the levelling compound cracking after drying.

If you have a wooden subfloor, it is important to seal all gaps/holes with sealant or a membrane and apply a waterproof primer on top. This is because wood absorbs moisture which can cause warping or buckling problems down the line if not prepared properly.

Step 3: Mix the self-levelling compound

The self-levelling compound is mixed with water (or another suitable solvent) according to manufacturer instructions. It is important to mix the compound thoroughly until it has a very smooth consistency and is free of lumps. This can be done easily with an industrial mixer which looks like an oversized egg beater.

Step 4: Pour the self-levelling compound

The self-levelling compound is poured onto the subfloor from the farthest corner of the room and worked towards the door. This needs to be done carefully to have even distribution across the surface. The compound should be spread out evenly using a trowel or roller if necessary.

Note that most levelling compounds have a minimum thickness of 3mm to maintain structural integrity. Too thin, and it may crack once dried!

Step 5: De-gas the self-levelling compound

Once the self-levelling compound has been poured, it is important to de-gas it to remove any air bubbles. This can be done using a spiked roller or a de-gassing brush. This will otherwise result in air pockets, which means the new substrate won&#;t be stable once dry. A little bit of residue bubbles won&#;t cause harm, however excessive bubbles can be an issue.

Step 6: Allow the self-levelling compound to dry

The self-levelling compound should dry completely before installing the floating floor. There should be no more than 5.5% moisture content reading before installation. You can easily check the moisture reading by purchasing a moisture meter, calibrating for concrete/brick surfaces. The drying time will vary depending on the thickness of the compound and the ambient temperature. The more airflow and open windows (unless it rains), the quicker the levelling compound will dry.

Are you in a rush to get the job done?

Installing waterproof floors like hybrid flooring over uncured levelling compounds can result in mould growth in the underlayment. Laying waterproof hybrid flooring with a plastic moisture barrier will minimise this risk, but won&#;t be as effective as giving proper drying and curing time. Whilst some companies may be willing to install before the levelling compound is dry, they usually won&#;t offer a warranty for any moisture-related issues that may occur down the line.

How Much Does Self-Levelling Compound & Subfloor Levelling Cost?

Most flooring companies in Sydney & NSW will sell residential-grade levelling compound anywhere from $35 &#; $50 per 20kg bag. You can cover around 2 square metres per 20kg bag, varying based on the severity of unevenness and the nature of the job. This averages out to $20 &#; $25 per square metre for supply only.

The market rate for the full subfloor levelling service is $40 &#; $90 per square metre in Sydney & NSW as of . Subfloor professionals will charge based on the type of subfloor, how uneven it is, and the total size of the job. Wooden subfloor will cost more because they require surface sealing with waterproof primer in advance.

• Supply Self-Levelling Compound: $20 &#; $25 per square metre.
• Concrete Subfloor Levelling (Material & Labour): $40 &#; $60 per square metre.
• Timber / Particleboard Subfloor Levelling (Material & Labour): $70 &#; $90 per square metre.
• FloorVenue can always beat the market rate. Reach out for a free quote!

FloorVenue stocks floor levelling compounds specialised for both residential and commercial use. Whether you&#;re looking for supply only or a full levelling service, do reach out to us. We highly recommend speaking to one of our friendly flooring experts as every job site and subfloor is different. Choose FloorVenue for a solution tailored to your situation!

Disclaimer:

1. This article offers general advice for subfloor levelling and applying self-levelling compounds. FloorVenue holds no responsibility for any decisions or actions made by individuals or companies following our advice as every product and job site is different.
2. Different flooring / levelling compound manufacturer guidelines vary and have their own application processes which should take precedence over general advice.

In the intricate realm of flooring installation and renovation, ensuring a surface that is impeccably smooth and level is of paramount importance. For those who seek to attain perfection in flooring, self-levelling compounds are indispensable. These compounds, a blend of cementitious materials and often polymers, serve as the preliminary layer in flooring, rendering uneven or rough surfaces perfectly smooth and flat.

Self-levelling compounds are specifically formulated to improve the flatness and uniformity of the substrate. Thereby creating an ideal base for the final floor covering, be it tiles, carpet, or wood. This guide explores the facets of self-levelling compounds, including their composition, modes of application, and inherent advantages.

These compounds are essentially the synthesis of cement, polymers, aggregates, and additives. Each plays a pivotal role in ensuring the compound&#;s performance, workability, and durability. Polymers augment the compound&#;s flexibility and adherence properties. On the other hand, the additives are integrated to modulate the flow, set time, and enhance other functional properties. The amalgamation of these components ensures that self-levelling compounds effectively rectify any substrate discrepancies, delivering a uniformly levelled surface ideal for any flooring type.

In the ensuing sections, we will delve deeper into the intricate details of self-levelling compounds. We will explore their diverse types, application methodologies, and the pivotal role they play in flooring installation

What is a self-levelling compound and what is it composed of?

A self-levelling compound is a highly specialised, hybrid flooring solution primarily utilised to rectify and mitigate imperfections in the substrate, creating an impeccably smooth, and level canvas for subsequent floor installations. It is a fluid material that autonomously levels out, filling in depressions and eliminating protrusions, hence, used extensively to correct surface irregularities like dips, bumps, or cracks on subfloors.

Detailed Composition:

The composition of a self-levelling compound is predominantly comprised of the following components, each contributing to its unique properties:

• Cement: Acts as the foundational base of the compound, providing rigidity and structure.
• Polymers: These are incorporated to enhance the compound&#;s flexibility and adhesion, enabling it to bond efficiently with diverse substrates, accommodating minor movements and fluctuations in the substrate without compromising integrity.
• Additives: Specific additives are integrated to modulate and optimise the flow characteristics and setting time of the compound, ensuring a seamless, even spread over the substrate and aiding in the attainment of a flat, uniform surface.
• Aggregates: These are granular materials that provide bulk, stability, and structure to the compound, aiding in achieving the desired consistency and thickness.
• Pigments: Some compounds may contain pigments to impart colour to the compound, which could be advantageous in certain aesthetic or functional applications.

Upon application, the self-levelling compound spreads and levels itself out due to its low viscosity and optimised flow properties, filling in low spots and levelling high spots, thus, creating a uniform, smooth surface. The refined balance of components in the compound ensures that it maintains its shape and structure once set, providing a stable and reliable base for subsequent floor coverings.

This foundational layer is pivotal for the longevity and quality of the overall flooring system, as it rectifies substrate irregularities, preventing future issues such as cracking, debonding, or uneven wear in the final floor covering.

Types of self-levelling compounds

There are three major types of self-levelling compounds. Understanding their composition dictates their use. Residential properties and commercial spaces will have different requirements, however, the ultimate goal is to achieve dimensionally stable and level surfaces.

Water-based compounds

• Application: Ideal for residential and light commercial spaces due to their cost-effectiveness and ease of application.
• Characteristics: These are usually less viscous, user-friendly, and emit lower VOCs (Volatile Organic Compounds).
• Substrates: Suitable for concrete, wood, and other standard subfloor materials.
• Limitation: They might not be suitable for areas with heavy loads or extreme conditions due to lower strength and resistance.

Latex-based compounds

• Application: Preferred for surfaces prone to movement or vibration, such as wooden floors, due to their enhanced flexibility.
• Characteristics: They exhibit superior adhesion and flexibility, reducing the risk of cracking or debonding.
• Substrates: Ideal for substrates like wood, which may exhibit movement or dimensional instability.
• Curing: Latex-based compounds often require longer curing times compared to their counterparts.

Epoxy-based compounds

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• Application: Predominantly used in industrial settings where high strength and resistance to chemicals, impact, and abrasion are required.
• Characteristics: They are characterised by high compressive strength, chemical resistance, and durability.
• Substrates: Best suited for concrete and steel substrates in demanding industrial environments.
• Limitation: These compounds are more complex to mix and apply and are usually more expensive than water and latex-based compounds.

Polymer-modified compounds

• Application: Suitable for a wide range of applications with enhanced performance characteristics.
• Characteristics: They combine the properties of polymers and cementitious compounds for improved adhesion, flexibility, and water resistance.
• Substrates: Can be applied to a variety of substrates including concrete, wood, and tiles.
• Versatility: They can be customised with additives to achieve specific performance requirements.

Fast-setting compounds

• Application: Ideal for projects with tight timelines where rapid setting and curing are crucial.
• Characteristics: They offer quick drying times, allowing for the swift progression to subsequent construction stages.
• Substrates: Suitable for most standard substrates including concrete and wood.
• Consideration: The fast setting time requires a quick and efficient application to avoid premature drying and curing.
• Application steps

Application steps

1. Surface Preparation

Before embarking on the application of a self-levelling compound, it&#;s critical to meticulously prepare the substrate to ensure optimal adhesion and performance of the compound. Start by thoroughly cleaning the surface, and removing any traces of dust, dirt, grease, oil, or any loose and deteriorating materials. This step is imperative as any contaminants left on the substrate can impede the adhesion of the compound, leading to potential failures in the future. For surfaces with stubborn contaminants like oil or grease, consider using a degreasing agent or an industrial cleaner.

Once the cleaning is complete, assess the substrate for any cracks, holes, or other damages and repair them using a suitable patching compound. After repairs, the application of a primer is crucial. A primer enhances the bond between the substrate and the levelling compound, preventing issues such as pinholing and bubble formation. Ensure that the chosen primer is compatible with the levelling compound and apply it as per the manufacturer&#;s instructions, allowing adequate drying time before proceeding to the next step.

2. Mixing the Compound

The mixing process is a pivotal step, and precision is key here. Accurate measurement of the compound and water (or any other recommended liquid) is essential. Follow the manufacturer&#;s specified ratio diligently to avoid inconsistencies in the mixture. Use a mechanical mixer to achieve a lump-free, homogenous consistency. Avoid overmixing as it could introduce air bubbles into the mix, which can lead to problems during application. Once mixed, the compound should be used immediately, considering its rapid-setting nature.

3. Application of the Compound

Pour the mixed self-levelling compound strategically, starting from the furthest point of the room and working your way towards the exit. The compound should be poured evenly over the surface, allowing it to flow and level itself out. Utilise a squeegee or a gauge rake to assist in spreading the compound to the desired thickness, ensuring it covers the entire area uniformly. Adhering to the manufacturer&#;s recommended application thickness is crucial to avoid issues such as cracking or insufficient coverage. For areas that are hard to reach or for detailing, a trowel can be used to manually spread the compound.

4. Curing Process

After application, the self-levelling compound requires a sufficient curing period to achieve its full strength and properties. The drying time can vary depending on the type of compound used, ambient conditions like temperature and humidity, and the thickness of the application. Generally, it ranges between 1 to 3 days. During this period, it is paramount to avoid any traffic or disturbance to the area to prevent imperfections or damage to the freshly applied compound. Adhering to the manufacturer&#;s recommended drying time ensures the compound is adequately set before installing the final floor covering.

Advantages of self-levelling compounds

Uniform and Smooth Surface

One of the primary advantages of self-levelling compounds is their ability to provide a highly uniform and smooth surface, an attribute that is crucial for the optimal installation of final floor coverings. These compounds meticulously fill in the depressions and rectify undulations on the substrate, eliminating irregularities and imperfections. The attainment of a smooth, flat surface is indispensable for the longevity and performance of floor coverings such as tiles, laminate, or carpet, ensuring they are laid evenly and securely.

Rapid Application and Setting

The application of self-levelling compounds is relatively swift and straightforward, which can significantly reduce the downtime in construction or renovation projects. Many of these compounds are formulated to set and cure rapidly, allowing for the progression to subsequent stages of the flooring installation in a shorter timeframe. This expedited setting is particularly advantageous in commercial settings, where minimising operational disruption is often a critical consideration.

Enhanced Durability and Strength

Self-levelling compounds are imbued with properties that impart enhanced durability and strength to the floor structure. They serve as a robust intermediary layer between the substrate and the floor covering, distributing loads and stresses more evenly across the surface. This uniform distribution of stresses mitigates the risk of cracking, deformation, and other structural damages to the floor covering, prolonging its lifespan and maintaining its aesthetic appeal over time.

Versatility and Compatibility

Self-levelling compounds exhibit immense versatility, being compatible with a variety of substrates including concrete, wood, and tiles. This versatility is augmented by the availability of different types of compounds, each tailored to meet specific requirements and conditions of the project. Whether it&#;s a high-traffic industrial floor requiring chemical resistance or a residential space needing aesthetic appeal, there is a suitable self-levelling compound that can cater to diverse needs and preferences.

Accommodates Varied Floor Coverings

The use of self-levelling compounds is not restrictive to specific floor coverings. Once cured, these compounds can accommodate varied types of floor coverings including tiles, carpet, vinyl, and wood, providing ample flexibility in choosing the desired aesthetic and functional attributes of the final floor. This ability to adapt to different floor coverings allows for greater design freedom and customisation, enabling the realisation of distinct architectural visions and preferences.

Things to consider

Substrate Condition and Preparation

Before applying a self-levelling compound, it&#;s crucial to thoroughly examine the substrate&#;s condition. Any presence of contaminants, loose materials, or structural damage on the substrate can compromise the adhesion and performance of the compound. Proper preparation, including cleaning and repairing the substrate, is fundamental to achieving optimal results. Substrate moisture levels should also be evaluated, as excessive moisture can lead to failures such as debonding or blistering of the compound.

Material Selection

Choosing the appropriate type of self-levelling compound is essential, considering the specific requirements and conditions of the project. Factors such as the substrate type, environmental conditions, desired drying time, and the intended floor covering should influence the selection. For instance, epoxy-based compounds may be more suited to industrial environments due to their enhanced strength and chemical resistance, while latex-based compounds might be preferable for surfaces prone to movement due to their flexibility.

Manufacturer&#;s Instructions

Adherence to the manufacturer&#;s instructions is paramount throughout the process, from mixing to application. Instructions typically include guidelines on the proper mixing ratios, drying times, and application thickness. Deviations result in inconsistencies, poor performance, or failures of the compound. Reading and following the product datasheet and guidelines ensures that the compound is prepared, applied, and cured correctly, optimising its performance and durability.

Ambient Conditions

The environmental conditions during the application and curing of the self-levelling compound can significantly impact its performance. Temperature and humidity levels should be within the recommended range to prevent issues such as improper curing, cracking, or poor adhesion. Protecting the area from direct sunlight, wind, or precipitation is also essential, particularly for outdoor applications, to avoid rapid drying or contamination of the compound.

Health and Safety

Given that self-levelling compounds contain chemical components, prioritising health and safety is crucial. Utilising appropriate personal protective equipment such as gloves, goggles, and masks is essential to prevent exposure to harmful substances. Adequate ventilation should be ensured in enclosed spaces to avoid the inhalation of fumes or dust. Additionally, any spills or residues should be promptly cleaned, adhering to the recommended disposal methods to mitigate environmental impact.

Budget and Cost-effectiveness

Economic considerations should also play a role in decision-making. While self-levelling compounds are a valuable investment for achieving high-quality floors, balancing the cost with the project requirements and budget is essential. Opting for cost-effective solutions without compromising quality and performance is crucial. Exploring various products and their cost implications can aid in making informed, economically sound decisions.

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