Performance of polymer-modified self-leveling mortars with high polymer–cement ratio for floor finishing

Abstract

Recently, polymer-modified mortar has been studied for proposed use on industrial floors as top coat with thin thickness, typically 5–15 mm. The purpose of this study is to evaluate basic properties of self-leveling materials using polymer dispersions as kinds of SBR latex, PAE and St/BA emulsions for thin coatings (under 3 mm in thickness). Superplasticizer and thickener have been included in the mixes to reduce bleeding and drying shrinkage as well as to facilitate the workability required. The self-leveling materials using four types of polymer dispersion are prepared with polymer–cement ratios of 50% and 75%, and were tested for basic characteristics such as density, flow, consistency change and adhesion in tension. The test results showed that the self-leveling mortars using PAE emulsion at a curing age of 28 days were almost equal to those of conventional floor using urethane and epoxy resins. The adhesion in tension of self-leveling mortars using SBR latex and PAE emulsion at a curing age of 3 days is over 1.67 MPa. It was noted that the consistency change is strongly dependent on the type of polymer dispersion. It is concluded that the self-leveling mortars with polymer dispersions can be used in the same manner as conventional floor-finishing materials using thermosetting resin in practical applications.