Self-Leveling Concrete: Importance and Techniques | XPS Blog

Build a stronger foundation.

As a contractor, you'll know that the best epoxy resin floors start with strong concrete foundations. If the concrete is too worn, or there's unevenness, or moisture, epoxy systems can, and often will, fail. But don't worry! There's plenty of ways to fix up concrete, such as self-leveling concrete. Uneven concrete surfaces, often caused by irregular ground or installation issues, often lead to significant flooring problems. Concrete leveling is an indispensable skill for any flooring business working with concrete.

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In this guide, we'll dive deep into the significance of mastering concrete leveling. From why it's necessary, to recommended equipment, to step-by-step techniques for installing self-leveling concrete to ensure your flooring projects stand the test of time.

Why Do I Need Level Concrete?

Concrete leveling is more than just a preparatory step—it's a foundational requirement. The installation of any system, whether it's polished concrete or epoxy, on uneven concrete sets the stage for system failure. It also poses safety hazards and, as Coxwell Law points out, opens you up to unnecessary liabilities! 

The need for level concrete should be obvious. And yet, too many contractors neglect to check their concrete foundations before installing epoxy resin. With self-leveling concrete, it doesn't have to be a hassle.

Safety, Efficiency, and Aesthetic Concerns

An uneven floor is an unsafe floor. Foot and vehicle traffic rely on a consistently leveled floor to travel safely! Not only that, but uneven concrete foundations make a job site unsafe for your contractors, too.

Beyond these practical issues, the visual appeal of the finished floor is always going to suffer when the floor is uneven. Clients should come to your business because you deliver safe, and beautiful, floors. Don't let them down!

What Do I Need To Level Concrete?

To effectively level concrete, you're going to need the right tools. Here are the recommended resources for a successful leveling project:

1. Angle grinder or large floor grinder. Make sure the tool you buy fits your job site's requirements!
2. Self-leveling compound for filling low spots and achieving a uniform surface.
• Underlayment options like Rapid-Set TRU are designed to self-level a concrete floor for an epoxy resin flooring system. Rapid-Set's solution is considered the best overall self-levelling underlayment!
• Overlayment choices such as the NXT LEVEL SP Self Leveling Concrete solution are perfect for polished concrete systems.
3. An epoxy coating system, like XPS brand's own ECTR kit, to give your concrete that polished finish.
4. Application tools and accessories like squeegees and trowels to facilitate the process. You'll also need a level to identify where your concrete needs to be fixed, and to check your work after the self-leveling concrete cures.
5. Safety equipment is always necessary when you're working with potentially hazardous resources and machinery.

How Do I Level Concrete?

Step One: Identify Low Spots

Survey the concrete floor and identify areas that are lower than the rest. These low spots are what you're going to focus on. Identify them by eye or use a large level for precision. You need to be able to recognize the problem before you try to fix it. It'll help you determine how much grinding you need to do, or how much self-leveling solution to apply.

If your floor is uneven because of a few higher spots rather than low spots, then your solution may not even involve self-leveling concrete. You may need to grind these spots down. For smaller spots, you can use a simple angle grinder, but a larger industrial-grade floor grinder is always a good investment for flooring businesses.

Step Two: Apply Self-Leveling Compound

Once you've identified the low spots, apply a self-leveling compound using a trowel or squeegee. Evenly spread the compound over the low areas, ensuring a smooth application. It'll level itself out (as the name implies), but you still need to be diligent and not apply too much compound, or too little.

Don't rush this step! It'll only add more time later. If you apply too little solution, and only realize after you've checked your work, you'll have to apply more solution and wait until that cures. If you apply too much, you'll have to grind it down.

Step Three: Allow the Self-Leveling Concrete Solution to Dry

Allow the self-leveling compound to dry, typically within 24 hours. During this time, the compound will spread and settle, filling in the low spots on the floor.

This is the easiest, but obviously most time-consuming, aspect of leveling concrete. You can't rush this step. Concrete needs to be fully cured and dried before you start applying any epoxy solution on top of it, or attempt to polish it.

Step Four: (OPTIONAL) Grind the Concrete Until Level

If the floor remains uneven after applying the compound, consider using a grinder to remove high spots and achieve a uniform surface.

Use your level! Check your work thoroughly and make sure your floor is consistently level across its entire area. Focus on any irregularities, whether they're high spots or low.

Step Five: Seal or Install

After you get that level concrete surface, you can either seal it with a concrete sealant for protection or put an epoxy flooring system on it! We have guides to read on our blog that will help you navigate any kind of concrete flooring system you'll install.

Conclusion

Level concrete is always necessary for any flooring system. You need strong foundations for your floors. This comprehensive guide will hopefully help you avoid potential flooring failures in the future, and save you both money and labor time in the long run! Whether you're working on polished concrete or epoxy floors, starting on the best foundation often guarantees success.

The different types of self-leveling compounds include cement-based, gypsum-based, epoxy-based, polyurethane-based, and hybrid formulations.  Regarding preparing a smooth, level subfloor for your flooring project, self-leveling compounds can be a game-changer. These specialized products are designed to flow, spread, and level out uneven surfaces, creating a consistently flat foundation for your final flooring installation.

As a homeowner or contractor, you’ll find a range of self-leveling compounds on the market, each with its unique properties and intended applications. 

What are the Different Types of Self Levelers Compounds

The different types of self-leveling compounds include cement-based, gypsum-based, epoxy-based, polyurethane-based, and hybrid formulations. 

1. Cement-Based Self-Leveling Compounds

Cement-based self-levelers are a type of self-leveling compound that are known for their durability, versatility, and cost-effectiveness.

These products are typically composed of a combination of cement, sand, and various additives that give them their unique properties. The cement base provides strength and stability, while the sand and additives help to enhance the flow, workability, and overall performance of the self-leveler.

Some key characteristics of cement-based self-levelers include:

Durability: The cement-based formulation makes these self-levelers highly durable and resistant to wear and tear, making them suitable for a wide range of applications, including residential and light commercial settings.

Versatility: Cement-based self-levelers can be used on a variety of subfloor types, including concrete, wood, and even existing floor coverings, making them a flexible choice for many projects.

Cost-Effectiveness: Compared to some other types of self-leveling compounds, cement-based products are generally more cost-effective, making them a popular choice for budget-conscious projects.

Easy Application: Cement-based self-levelers are known for their good flow and workability, allowing for easy application and a smooth, level finish.

Due to these attributes, cement-based self-levelers are often the go-to choice for many residential and light commercial flooring projects, where a durable, cost-effective, and versatile self-leveling solution is required.

2. Gypsum-based self-levelers  

Gypsum-based self-levelers are a type of self-leveling compound that are primarily composed of gypsum rather than cement. These products offer a few key advantages over their cement-based counterparts. Firstly, they are known for providing a smoother, more uniform finish to the subfloor compared to cement-based formulations. This can be beneficial in achieving a seamless, high-end look, particularly in interior, low-traffic applications such as residential bedrooms or office spaces where a pristine subfloor finish is the primary goal. 

Also, gypsum-based self-levelers typically have quicker drying times than cement-based options, allowing for faster project completion. This faster drying time is another factor that makes gypsum-based self-levelers better suited for interior, light-duty environments where the subfloor needs to be ready for finishing quickly.

While gypsum-based self-levelers may not offer the same level of durability and versatility as cement-based products, they excel in providing a refined, high-quality subfloor surface in the right applications. Contractors and homeowners should carefully consider the specific needs of their project when deciding between gypsum-based or cement-based self-leveling compounds to ensure the best possible outcome.

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3. Epoxy-based self-levelers

Epoxy-based self-levelers are a type of self-leveling compound that are formulated with epoxy resins as their primary binding agent. These products are known for their exceptional performance characteristics, making them well-suited for commercial and industrial applications.

The epoxy-based composition of these self-levelers offers exceptional chemical resistance, allowing them to withstand exposure to a wide range of chemicals, oils, and other potentially damaging substances. This makes them an ideal choice for environments where the subfloor may be subject to spills or exposure to harsh chemicals, such as in manufacturing facilities, warehouses, or commercial kitchens.

In addition to their chemical resistance, epoxy-based self-levelers also provide a high degree of durability and wear resistance. They can withstand heavy foot traffic, the movement of equipment, and other types of heavy-duty use without compromising the integrity of the subfloor. This makes them a popular choice for commercial and industrial settings where the flooring needs to be able to stand up to demanding conditions.

Another benefit of epoxy-based self-levelers is their moisture resistance. These products can be used in damp or humid environments without the risk of degradation or damage, making them a versatile option for a variety of project types.

4. Polyurethane-based self-levelers

Polyurethane-based self-levelers are a type of self-leveling compound that utilizes polyurethane as the primary binder. Unlike other self-leveler types, polyurethane-based formulations offer added flexibility, allowing the material to better accommodate minor subfloor movement or substrate deflection without cracking or delaminating. 

These self-levelers exhibit a higher degree of moisture tolerance compared to some other formulations, making them a smart choice for damp environments or areas prone to moisture exposure. Polyurethane-based self-levelers’ flexible and moisture-resistant properties allow them to be used in a wider range of applications, including residential, commercial, and even some industrial settings. 

This adaptability makes them a valuable option for projects where a more forgiving, impact-resistant, and moisture-tolerant subfloor surface is required, such as in areas with potential for subfloor movement, damp conditions, or the possibility of heavy impacts on the flooring.

5. Hybrid self-levelers

Hybrid self-levelers are a type of self-leveling compound that combines two or more different binder technologies to create a product that leverages the strengths of multiple formulations. The goal of hybrid self-levelers is to provide a more versatile and high-performing solution compared to traditional single-binder self-levelers. 

The key advantage of hybrid self-levelers is their ability to deliver a tailored set of performance characteristics that may not be achievable through a single-binder approach. This allows contractors and specifiers to select a self-leveling compound optimized for the specific demands of the project at hand. As the self-leveler market continues to evolve, hybrid formulations are becoming increasingly common, allowing for innovative solutions that combine the best attributes of multiple binder technologies.

Factors to Consider When Choosing a Self-Leveling Compound

When choosing a self-leveling compound for a flooring project, you should consider substrate conditions, traffic levels, thickness requirements, chemical exposure, and curing time.

1. Substrate Conditions: The condition and composition of the existing subfloor or substrate are critical considerations. Self-leveling compounds need to be compatible with the substrate material, whether concrete, wood, or another surface. Factors like moisture levels, porosity, and existing coatings or contaminants must be evaluated to determine the appropriate self-leveler.

2. Intended Use and Traffic Levels

For high-traffic commercial or industrial environments, the self-leveler needs to be able to withstand heavy foot traffic, rolling loads, and potential impacts. These types of spaces, such as retail stores, warehouses, or manufacturing facilities, require a more robust and durable self-leveling compound.

Beyond just traffic levels, the intended use of the space can also influence the necessary performance characteristics of the self-leveler. For example, in areas that may be exposed to chemicals, oils, or other potentially damaging substances, such as commercial kitchens or laboratories, the self-leveler should have superior chemical resistance to prevent degradation or discoloration.

3. Thickness Requirements

Some self-levelers are best suited for thin applications, typically ranging from 1/8 to 1/2 inch, while others can be applied in thicker builds, up to 1-2 inches or more, to address more substantial substrate irregularities or larger voids.

The self-leveler’s ability to maintain a smooth, uniform surface finish, regardless of the applied thickness, is crucial. Inconsistencies or imperfections in the surface finish can negatively impact the final floor appearance.

Thicker self-leveling applications may require specialized equipment and installation techniques, such as larger pumps or mixing apparatus, to ensure a consistent and well-blended mixture. The curing time and drying rates may also differ for thicker builds compared to thinner applications.

4. Chemical Exposure

Spaces like commercial kitchens, laboratories, manufacturing facilities, automotive repair shops, and pharmaceutical production areas are examples where chemical exposure is a significant concern. Self-levelers with poor chemical resistance may degrade, discolor, or break down prematurely when exposed to these harsh chemicals, compromising the integrity and longevity of the flooring system.

In contrast, self-levelers with more basic cement or calcium-based compositions may be more susceptible to chemical attack, leading to surface deterioration, pitting, or other visual and structural issues over time.

5. Curing Time and Installation Logistics

The curing time of a self-leveling compound directly impacts the timeline and workflow of the flooring installation project. Faster-curing self-levelers can allow for quicker turnaround times and faster access to the finished floor, which is especially beneficial in commercial or high-traffic settings where downtime is limited.

Some self-levelers cure and dry within hours, while others may take a full day or longer to fully cure. The curing time can be influenced by factors such as the product’s formulation, the thickness of the application, and environmental conditions like temperature and humidity. Selecting a self-leveler with an appropriate curing time is essential for ensuring the project stays on schedule and meets the client’s timeline requirements.

6. Type of Professionals

When choosing a self-leveling compound, evaluate the expertise and reputation of the self-leveling company or flooring professionals you plan to work with. Look for a provider with extensive experience in projects similar to yours, whether commercial, industrial, or residential. This ensures they have the necessary knowledge and skills to deliver a high-quality installation that meets your specific requirements.

Also, it’s important to select a self-leveling company with a proven track record of quality workmanship, reliable service, and a commitment to addressing any issues that may arise during or after the installation process. The availability of warranties or guarantees offered by the self-leveling company can also provide an extra layer of assurance and peace of mind should any unforeseen challenges occur.

Southside Concrete Polishing is a reputable company that offers a wide range of self-leveling compound solutions and expert installation services. Our team of experienced professionals can assist you in selecting the right product and provide a seamless installation process tailored to your project’s needs. You can reach out to us to discuss your self-leveling compound requirements and receive a personalized recommendation and quote. 

When would you use a rapid-setting self-leveler?

You would use a rapid-setting self-leveler when you need a quick turnaround, such as in renovation projects or commercial spaces that need to be back in service quickly. The rapid-setting nature of these products allows for a much faster curing time compared to standard self-leveling compounds, enabling you to get the floor ready for the next stage of the project in a shorter timeframe.

How do you ensure proper mixing and application of self-leveling compounds?

To ensure proper mixing and application of self-leveling compounds, you must adhere to the manufacturer’s instructions, use the correct equipment, and have experienced installers performing the work.

Carefully following the manufacturer’s guidelines for mixing ratios, water addition, and mixing time is essential to achieving the desired consistency and performance of the self-leveling compound. Using the recommended mixing equipment, such as a drill-mounted paddle mixer, helps to thoroughly blend the components and minimize the introduction of air bubbles.

Can self-leveling compounds be colored or customized?

Yes, some self-leveling compounds can be colored or customized to achieve specific aesthetic goals. Manufacturers often offer the ability to tint the self-leveling product with pigments or add decorative aggregates to the mix.

Tinting the self-leveling compound allows you to match or complement the space’s desired color scheme, providing design flexibility. The addition of decorative aggregates, such as colored quartz or metallic flakes, can also create unique visual effects and textures within the finished floor.

Can self-leveling compounds be used over existing flooring materials?

Yes, in many cases, self-leveling compounds can be used over existing flooring materials, but it is important to properly prepare the surface and ensure compatibility with the existing flooring.

Before applying a self-leveling compound over an existing floor, it is crucial to thoroughly inspect the condition of the existing flooring and ensure it is well-bonded to the substrate. Any loose, damaged, or unsuitable flooring materials should be removed.

The surface of the existing flooring must also be properly prepared, often by mechanical means such as grinding or shot blasting, to create a rough, porous profile that will allow the self-leveling compound to adhere effectively. Applying a suitable primer or bonding agent may also be necessary to ensure a strong bond between the self-leveling compound and the existing floor.

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