Concrete Slabs

CONCRETE SLABS
Steel Trowel..Helicopter..Bull Float

And how to prepare a steel trowel slab for tiling.
Tiles With Style 181 Lake Rd Port Macquarie NSW 2444 Australia www.tileswithstyle.com.au
Specific Gravity
and its effect on concrete
2 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 KG/Litre
Water Cement Sand Aggregate
Lighter material rises to top; heavier material sinks to bottom.

CONCRETE SLABS
The Process
Fine Particles - cement, fine sands, gypsum, lime and other fillers (set retarders, plasticisers, accelerators, strengtheners etc) Coarse Aggregates - graded gravel, sand. Finish - steel trowel. Action - helicopter (power float) or bull float. Result - a hard, shiny, dense surface.
Cement Slab
Just after placement
All components are evenly dispersed.

Cement Slabshortly after levelling
Concrete begins to bleed water. This water carries the fine particles to the surface (cement, lime, additives etc).
Cement SlabAfter compacting with helicopter

Note chalky, mottled appearance
Bleed water has evaporated, leaving behind a surface layer rich in pure cement and fines. Top surface now very dense, hard and compacted. Surface also prone to carbonation (chalkiness), which results in surface shrinkage.
Laitance
Cement Slab
Finished slab
Surface now features a layer of cement dust and carbonated chalk This is often called laitance.
CONCRETE SLABS
Helicopter or Power Float Finished Slabs...
Note surface moisture still present
water is drawn to the surface, bringing an abundance of cement and fine particles. pure cement is compacted into the top layer of the slab. Coarse aggregates are pushed further to the bottom of the slab. The top of the slab is a very dense, non-porous surface layer that has a very low level of surface pores.
CONCRETE SLABS
Bull Float Slabs...
Note very wet surface layer
water is drawn to the surface, which brings with it an abundance of cement and fine particles. It does not compact the top layer of the slab. Rather, it leaves a relatively thick layer (1-2mm) of uncompacted pure cement on the surface, high in water content. It forms a very weak, poorly hydrated surface layer that has a high level of surface pores.
CONCRETE SLABS
Power Float and Bull Float Slabs...
Helicopter slabs - very thin, hard, dense surface layer. Bull float slabs - thicker, more chalky and weaker layer. Both are not suitable for tiling.
TILE FAILURE CASE STUDY
Note very dense top layer of slab
Water drops applied and noted to bead
Slab damped down and masses of shrinkage cracks noted
Acid applied and reacting strongly
Acid has removed top layer of pure cement to expose sand and aggregate
CONCRETE SLABS
Pure cement is unstable:
it is highly reactive with water & humidity it has high rates of shrinkage it is prone to carbonation (a reaction with carbon dioxide and the free lime in cement which forms calcium carbonate (chalk))
Sand and blue metal gravel are very stable. Aggregates are used in concrete in order to reduce this instability in cement.
CONCRETE SLABS
Wood Float Finish
CONCRETE SLABS...Wood Float Finish
porous, flat surface which provides excellent key for tile primers and adhesives.
Better dispersement of aggregates and cement throughout slab, particularly on surface. These exposed aggregates present a stable surface for adhesion. Cement paste will shrink and is not stable. Better surface cure leading to more resilient slab surface.
WOOD FLOAT IS THE PREFERRED FINISH FOR ALL SLABS TO BE TILED

CONCRETE SLABS
Laitance
The thin layer of powdery substances on the very top surface of a concrete slab. The main causes are: overworking the surface. poor mix design (too wet; adding additional water). Not waiting for bleed water to evaporate and floating or trowelling this water back into the concrete slabs surface. The concrete paste becomes diluted, causing the concretes surface to weaken. Applying water to the surface during finishing . Dry-shaking neat cement on the surface to speed finishing. Premature wetting of slab - hosing too early or exposure to rain. Lack of proper curing (allowing the surface to rapidly dry). Allowing the surface to freeze.
CONCRETE SLABS
LAITANCE
The strongest and least permeable area of the slab needs to be the surface, to successfully carry its designed traffic or overcoating (tiles, carpet etc). Laitance doesnt allow for this type of strength and permeability. Ceramic tile primers and adhesives applied over laitance can and will come loose from the substrate resulting in a failure. To avoid laitance, steer your builders concrete crew or subcontractor away from improper finishing and curing methods, and from increasing the water/cement ratio on the slab surface.
Many types of bonded coverings
Tiles...
Timber...
Vinyl...
CONCRETE SLABS
Testing for Laitance Wipe the surface of the concrete with a dark cloth ... if white powder is present (laitance), it must be removed. Pour water on the concrete in random areas.
If it puddles out and leaves the concrete wet you have a porous substrate. (Go to next page for notes on porous slabs) If water beads, this indicates that further surface preparation steps are necessary.
A concrete acid test will indicate if laitance is present. Laitance reacts readily with Hydrochloric Acid. Use 35% hydrochloric acid solution diluted 10:1 with water. If the acid immediately fizzes, laitance is present and must be removed by the appropriate method.
CONCRETE SLABS
Porous Slabs
Water readily soaking into the top of a slab indicates a porous surface. WARNING: some slabs are too porous, and will cause primers to flash dry on the surface (ie. dry instantly). The primer will not have time to penetrate the pores of the slab, and will stay on the surface only, very poorly bonded. Any product applied to this primer will not bond to the slab. Always soak porous slabs with plenty of water before priming. Apply the primer immediately after all surface water has evaporated.
CONCRETE SLABS
Testing For Laitance
Note water beading on hard, dense layer of cement and chalk

CONCRETE SLABS
Acid Test
Note instant fizzing indicates reaction with cement and chalk
Fizzing begins to slow after approx 30 seconds as cement and chalk is dissolved
CONCRETE SLABS
Pre Tiling Preparation
CHEMICAL PREPARATION
Acid Etching is one way of removing laitance. It also ensures that sand and aggregate are exposed, allowing the primer or adhesive to bond directly to them. If you do bond to laitance or cement paste layer, this will shrink with time and is unstable. Tiling over laitance will result in tile system failure. Use 35% hydrochloric acid solution diluted 10:1 with water. Wet down slab initially with water to ensure that the acid affects only the top layer of the slab. The solution should be left on the surface until all foaming ceases (typically 1-2 minutes). Wash off immediately with water. Remove any unreacted acid with Bicarb of Soda, also known as Sodium Bicarbonate, diluted into your rinse water.
CONCRETE SLABS
Pre Tiling Preparation
CHEMICAL PREPARATION (continued) The surface profile should have a fine sandpaper texture (60 to 100 grit range). Etching exposes the sand and aggregate, it does not remove grease, oil, or other foreign matter. Therefore, if these contaminants are present, surfaces must be cleaned with a biodegradable detergent after etching. If there are oil and grease spots present, "do not" attempt to remove them with solvent. Doing so will dilute them, driving them deeper into the porous concrete surface. There are several types of environmentally safe degreasers available.
CONCRETE SLABS
Acid Etching
Note how water readily soaks into etched surface

CONCRETE SLABS
Acid Etching
Note how etched surface contains many sand particles
Non etched surface remains shiny and dense
CONCRETE SLABS
Curing Compounds, Bond Breakers & Hardeners Curing compounds are generally based on: water based technologies such as PVA, SBR, or acrylics wax emulsions (water or solvent borne) solvent based chlorinated rubber solvent based hydrocarbon resins integral curing compounds in wet mix concrete In all cases, consult the builder or concreter as to what type of curing compound was used. Surface hardeners and some curing compounds, which are beneficial to the concrete, can be very detrimental to primers and adhesives; therefore, they must be effectively removed.
CONCRETE SLABS
Testing for Bond Breakers & Curing Compounds etc Pour water on the concrete in random areas. If it puddles out and leaves the concrete wet you have a porous, acceptable substrate. If water beads, this indicates that further surface preparation steps are necessary. Observe the perimeters of the slab near walls for the presence of compounds that may not have worn off during construction. A concrete acid test will indicate if previous sealers, curing agents, or other contaminates are present. Use 35% hydrochloric acid solution diluted 10:1 with water. If there is no fizzing, or fizzing is random, contaminates are present and must be removed by appropriate method.
CONCRETE SLABS
Testing for curing compounds etc
Note strong beading of water with little or no penetration signals presence of curing compound or release agent
CONCRETE SLABS
Removing Curing Compounds etc MECHANICAL PREPARATION Shot Blasting is a rapid, dust free procedure that leaves the substrate clean and dry. Scarifiers mechanically abrade the surface to create a profile through a rotating action. Scabblers are typically used to remove failed resurfacing materials that are 5-10mm thick by impacting the surface. Pressure Washing By incorporating sand, using a sand injector, at 3000 psi, desirable profiles can be created. Consult the machine manufacturers for more information.
CONCRETE SLABS
Summary
Laitance does occur, and tile system failures are far too common on slabs. Always be aware of how the slab was finished prior to commencing tiling. If in doubt, conduct the water and acid tests as detailed in this presentation. Test for the presence of curing or hardening compounds. Encourage concreters to employ good concreting practices, and to finish their slabs with a wood float finish where possible. Always use the best possible surface preparation techniques and primer and adhesive systems to overcome problems in the slabs surface.
CONCRETE SLABS
Remember that, in 100% of cases, it is the tilers choice to accept a substrate as suitable for tiling. Tiles With Style can assist with on site recommendations, but the responsibility ultimately lies with the tiler.

Concrete Slabs

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CONCRETE SLABS

Steel Trowel..Helicopter..Bull Float

Water Cement Sand Aggregate

Lighter material rises to top; heavier material sinks to bottom.

All components are evenly dispersed.

Cement Slabshortly after levelling

Cement SlabAfter compacting with helicopter

TILE FAILURE CASE STUDY

Note very dense top layer of slab

TILE FAILURE CASE STUDY

Water drops applied and noted to bead

TILE FAILURE CASE STUDY

Slab damped down and masses of shrinkage cracks noted

TILE FAILURE CASE STUDY

Acid applied and reacting strongly

TILE FAILURE CASE STUDY

CONCRETE SLABS...Wood Float Finish

WOOD FLOAT IS THE PREFERRED FINISH FOR ALL SLABS TO BE TILED

Many types of bonded coverings

Note water beading on hard, dense layer of cement and chalk

Note instant fizzing indicates reaction with cement and chalk

Note how water readily soaks into etched surface

Note how etched surface contains many sand particles

Non etched surface remains shiny and dense

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