Warehouse floor hardeners (dry-shake)

The work, step by step

General guidance based on the manufacturer data sheets. Site conditions differ: confirm the system with MCT before you start. Where we do not name a product, ask us and we will confirm the right one.

1. 1

   Step 1: Plan the slab

   The slab should be at least 15 cm thick with an adequate cement content and a suitable admixture (Sikafloor-5 Chapdur Premix (PK) p.2). Do not use concrete where cement is partly replaced by fly ash; it makes the mix sticky (Sikafloor-2 SynTop p.2). Fibres can reduce shrinkage cracking (Sika Crackstop Fiber 6 mm p.1); structural fibre use needs an engineer's design (SikaFiber Force-60 p.2).

   Sika Crackstop Fiber 6 mm Sika Request a quotation

   For most types of non-structural concrete and cementitious mortars which need to reduce the incidence of shrinkage cracking: Ground bearing slabs, Screeds and overlays, Renders and plasters, Precast concrete elements, Sprayed applications, Extruded concrete. (TDS p.1)

   SikaFiber Force-60 Sika Request a quotation

   For most types of in-situ cast structural concrete and sprayed concrete to distribute stresses, increase structural properties or increase abrasion resistance. Sprayed concrete: Excavation stabilisation in tunnelling and mining, Rock and ground stabilisation, Temporary stabilisation, Replacement … (TDS p.1)

2. 2

   Step 2: Broadcast the dry-shake at the right time

   Start when a thumb pressed hard leaves a print of about 3–5 mm (Sikafloor-5 Chapdur Premix (PK) p.2). Chapdur uses 3 kg/m² for light duty, 4–5 kg/m² medium and 6 kg/m² heavy (p.2). QuartzTop and SynTop are applied at about 3–5 kg/m² and MetalTop at about 5–7 kg/m² (Sikafloor-3 QuartzTop (PK) p.2; Sikafloor-2 SynTop p.2; Sikafloor-1 MetalTop p.2).

   Sikafloor-5 Chapdur Premix (PK) Sika Professionals only

   Sikafloor®-5 Chapdur Premix (PK) is added to slab surface to improve their resistance to abrasion and inhibit dust formation. Sikafloor®-5 Chapdur Premix (PK) is suitable for all floor exposed to severe mechanical wear for example: Warehouse, Quays, Traffic lanes, Engineering workshop, Car-parks,… (TDS p.1)

   Pack

   25 kg bag

   Sikafloor-3 QuartzTop (PK) Sika Professionals only Request a quotation

   Sikafloor®-3 QuartzTop (PK) may only be used by experienced professionals. (TDS p.1,2)

   Temperature stated in TDS

   +5 °C min. / +30 °C max (TDS p.2)

   Sikafloor-2 SynTop Sika Professionals only Request a quotation

   Sikafloor®-2 SynTop provides a hard wearing, nonmetallic dry shake topping for monolithic floors. (TDS p.1)

   Temperature stated in TDS

   +5 °C min. / +30 °C max (TDS p.2)

   Sikafloor-1 MetalTop Sika Professionals only Request a quotation

   Sikafloor®-1 MetalTop provides a non-staining, ultrahard wearing, metallic dry shake topping for monolithic floors. (TDS p.1)

   Temperature stated in TDS

   +5 °C min. / +35 °C max (TDS p.2)

3. 3

   Step 3: Float and trowel

   Once the powder is evenly wetted from below, compact with a low-speed power trowel held flat, then smooth with blades (Sikafloor-5 Chapdur Premix (PK) p.2). Sikafloor-931 Finishing Aid speeds finishing and allows more dry-shake to be worked in; apply no more than 70 g/m² at a time (p.1, p.2).

   Sikafloor-931 Finishing Aid Sika Professionals only Request a quotation

   Sikafloor®-931 Finishing Aid is used on commercial and industrial polished concrete floors in dry-shake applications. Please note: The Product may only be used by experienced professionals. (TDS p.1)

4. 4

   Step 4: Cure and seal immediately

   Spray Sikafloor ProSeal W or ProSeal-22 immediately after finishing (Sikafloor-2 SynTop p.3). For metallic MetalTop use solvent-based ProSeal-22 only (Sikafloor-1 MetalTop p.3; Sikafloor ProSeal W p.2).

   Sikafloor ProSeal W Sika Professionals only Request a quotation

   Sikafloor® ProSeal W is used for optimum curing and sealing of fresh concrete floors and structures. (TDS p.1)

   Temperature stated in TDS

   +10 °C min. / +30 °C max (TDS p.2)

   Sikafloor ProSeal-22 Sika Professionals only Request a quotation

   Sikafloor® ProSeal-22 is used for optimum curing and sealing of fresh concrete Floors and structures Curing compound in order to limit surface drying and cracking Provides curing and sealing for Sikafloor® dry shake hardeners Anti-dust treatment and improve… (TDS p.1)

   Temperature stated in TDS

   +10 °C min. / +30 °C max (TDS p.2)

   Pack

   25 l pails and 200 l drums.

5. 5

   Step 5: Saw-cut and seal joints

   Saw-cut joints only after 24 hours (Sikafloor-5 Chapdur Premix (PK) p.3) and within two days (Sikafloor-3 QuartzTop (PK) p.2). Clean off saw slurry without delay, then fill joints with Sikaflex PRO-3 (Sikafloor-2 SynTop p.3).

   Sikaflex PRO-3 Sika

   Horizontal and vertical interior and exterior sealing joint applications: Food industry, Cleanrooms, Sewage treatment plants, Tunnels Sealing horizontal and vertical joints for:, Floors, Pedestrian and traffic areas. (TDS p.1)

   Temperature stated in TDS

   −40 °C to +70 °C (TDS p.2)

   Pack

   600 ml cylindrical foil pack

6. 6

   Step 6: Existing dusty slabs: liquid hardener

   Sikafloor CureHard-24 hardens and dust-proofs old or new concrete (p.1). On new floors wait 7–14 days after placing (p.3). Scrub it in for at least 30 minutes, re-wet and rework, then rinse off the excess (p.3, p.4).

   Sikafloor CureHard-24 Sika Professionals only

   Horizontal old or new concrete surfaces, where a hard surface with light to moderate abrasion resistance is required e.g. (TDS p.1)

   Temperature stated in TDS

   +5 °C min. / +35 °C max (TDS p.2)

7. 7

   Step 7: Open to traffic

   Chapdur floors take foot traffic after 1–2 days, light vehicles after 7–10 days, and are fully cured after 28 days (Sikafloor-5 Chapdur Premix (PK) p.2).

Steps and product facts are taken from the manufacturer data sheets (page cited). Products are named only where the data sheet confirms the use; quantities follow a site visit or photos. General guidance: check the data sheet or ask us before you start.