Trimix flooring is a unique kind of flooring that is typically utilised in industrial settings. Its resistance to wear and tear is excellent. The industrial sector is where it is usually used since light load cranes, light weight carrier vehicles, and machine foundation all require hard surfaces. Typically, a rich combination of 1:1:2 is used for improved wear and tear. The concrete mix used for trimix is 1:1:5:3 (1 cement, 1.5 sand and 3 stone aggregates).
The amount of reinforcement required for this flooring depends on the thickness of the flooring; concrete is typically 100 to 200 mm thick over PCC (1:4:8) and 230 to 300 mm thick over a well-prepared stone subbase.
For heavy-duty locations, PCC bases should be maintained to a maximum thickness of 100 mm in industrial flooring and should be the same thickness as concrete at 150 mm.
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Trimix flooring equipment
Product specifics
A double beam screed vibrator, a trowel cum floater, a vacuum pump, and a groove cutting machine make up the trimix flooring machine. Dewatering systems provide certain benefits over conventional concrete slabs. It improves the floor’s tensile strength. In comparison to conventional concrete slabs, it lowers the water-to-cement ratio. When dewatering technologies are applied, the first strength improvement occurs more quickly. When vacuum dewatering technologies are utilised, abrasion resistance also increases.
Double beam screed vibrator: RCC flooring may be made consistent by using double beam screed vibrators. The substantial weight it avoids reveals the greater compaction difference.
Vacuum pumps, 7.5 HP and 5 HP: Vacuum pumps are used to remove any air bubbles that become trapped during concrete laying. Because it enables the cement to reach the higher layers, the floor is stronger as a result. The three mats—filter, suction, and top—are designed to only suction surplus water and prevent cement from rising.
Floater cum trowel: Powered by a 3 HP geared motor, this trowel is utilised to give the RCC flooring a superb finish. The gearbox is robustly built for abrasive conditions in India. The finishing dish, which is 4 mm thick, is crucial to maintaining a long life. The best completed floor may be achieved by using this machine as a trowel. It is fairly simple to go from a floater to a trowel.
See also: Self compacting concrete (SCC): Know everything about this type of concrete
Specifications for trimix flooring
Tools and materials needed:
It is necessary for all masonry equipment to be on hand. However, the following specific equipment is needed:
- Trowels cum floaters
- Pump for vacuum dewatering
- Vibratory double-beam screed
- Groove Cutter
Materials such as Mix 1:1:2 and floor hardener must meet specifications.
Flooring instructions:
- Water and properly ram the sub-base to prepare it for flooring. Verify that there are no remaining loose things. Lay a 150 mm thick layer of adequately compacted stone or boulder soling at a depth of 230 to 300 mm on a level surface.
- PCC construction (over stone soling) must maintain a floor slope. The maximum thickness of PCC is 100 mm.
- Trimix must be done in panels, each of which must be 3.5 metres long. The necessary reinforcing bar must be set in layers of one or two, with a 50 mm concrete cover (it may differ as per standard).
- In order to remove extra water from wet concrete’s top layer without removing the cement or sand particles, vacuum dewatering devices are helpful.
- The concrete is levelled with a first round trowel immediately following concerting, ramming, or vibrating with a screed vibrator. Not only will it strengthen the concrete, but it will also make the floor more resistant to abrasion.
- Additionally, it is usually a good idea to add a hardener to strengthen the floor’s resistance to abrasion while completing the floor’s surface with a floater machine. By adopting this approach, shrinkage cracks are also reduced.
- Polyurethane fibres and floor hardeners should be applied to concrete in tiny amounts to prevent shrinkage cracks and boost abrasion. The makers specify how much fibre and hardener to use.
- When a big area needs to be floored, casting concrete flooring in panels is a laborious and time-consuming operation but prevents shrinkage cracks and serves as expansion joints.
- Without any construction joints, the concrete is laid down in panels. After 7 to 10 days, when the concrete has not fully cured, panel joints should be cut using a cutting saw. The resulting gap is filled with polysulfide or sealants.
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Trimix flooring process
Objective
This work method outlines the standards to be followed for podium and basement flooring made of trimix, or vacuum dewatered concrete, which is typically 75 mm thick.
- Application: All trimix flooring projects are covered by this process.
- Drawings, standard specifications, and BOQ are reference documents.
- The Project Manager is in charge of overseeing the procedure’s full implementation.
- Only authorised persons should handle the operations according to safety precautions. Utilise PPEs such as gloves, a helmet, goggles, and gumboots.
- M-25 grade concrete, steel tape, alignment thread, water-level or level instrument, M.S. sidetrack rails 50 mm thick, levelling beam, wire brush, concrete float, surface vibrator, mechanical trowel, vacuum matting, and vacuum pump were the materials, equipment, and tools utilised.
Procedure
– The area where the concrete will be applied should be chopped, completely cleaned, clear of dust, oil, and other loose materials, and wetted to provide a just-moist surface. One expansion should cover an area of between 80 and 100 square metres.
– The levelling beam and surface vibrator will be installed on two sidetrack rails that must be secured to the correct levels and spaced apart by around 4 m. M.S. rails must also be installed where necessary at the beginning and conclusion.
– Concrete of the M-25 grade must then be physically laid out in horizontal layers. To achieve the necessary compaction, a surface vibrator needs to be operated over an area measuring 5 to 6 sq m.
– In order to complete the concrete at the correct level, this procedure is resumed, and the surface vibrator is operated a second time together with a levelling beam. To remove extra water from the levelled concrete using a vacuum pump, vacuum mats of 4 m x 4 m must be laid on it.
– It usually takes 1.5 to 2.0 minutes to complete this process for each centimetre of concrete thickness. (i.e., 15 min). After that, skin floaters that are powered should be used to begin the flotation process. This should be done repeatedly until the desired finish is achieved.
– Ponding must be used to begin curing after the surface has dried and must be continued for a minimum of 7 days. Concrete joints are created by cutting the already-placed, fully-cured concrete to create grooves that are 40 mm deep and 4 mm wide.
– These joints must be cleaned and filled with dry sand mixed with bitumen grade (80-20). Expansion joints must be positioned in accordance with the plans and constructed using boards made of a compressible material that is 25 mm thick. Fill the top 15 mm of the joint with dry river sand and bitumen grade (80-20).
FAQs
What is trimix flooring used for?
Trimix flooring is often used in commercial and industrial settings, such as warehouses and factories because it is durable and able to withstand heavy loads. It is also commonly used in the construction of roads, bridges, and other infrastructure.
What are the benefits of trimix flooring?
Trimix flooring is known for its durability and strength, as well as its resistance to wear and tear. It is also easy to maintain, as it does not require waxing or other special treatments.