Case Background
In the interior flooring construction of a commercial building in Germany, self-leveling mortar was required for floor leveling. Traditional cement-based self-leveling mortars often suffer from low early strength, poor crack resistance, and insufficient wear resistance, which fail to meet the requirements for high-quality floor construction. To address these issues, the construction team decided to add redispersible polymer powder to the self-leveling mortar to enhance its performance. Our company provided the corresponding solution and samples for testing. After the tests were passed, the customer purchased our redispersible polymer powder in large quantities for both their own use and local distribution.
Application Plan
Material Selection
The construction team chose RDP Mikrant 6115L, a polymer powder known for its excellent
dispersibility and film-forming properties.
Formulation Design
Base Materials: Cement, sand, heavy calcium powder, anhydrous gypsum, etc.
Polymer Powder Dosage: Based on preliminary experiments, the optimal dosage of polymer powder was determined to achieve the best overall performance of the self-leveling mortar.
Construction Process
Substrate Preparation: Clean the floor of impurities to ensure it is flat, dry, and free from hollow sounds and cracks.
Mixing: Combine cement, sand, polymer powder, and other materials in proportion, then add water and stir until the polymer powder is fully dispersed.
Pouring and Leveling: Pour the mixed self-leveling mortar evenly onto the floor. The self-leveling property allows it to spread naturally without manual troweling.
Curing and Grinding: After construction, allow the self-leveling mortar to cure and dry. Then, grind the surface to ensure it is smooth and flat.
Performance Improvement
Flowability and Leveling
The addition of redispersible polymer powder RDP Mikrant 6115L significantly increased the
flowability of the self-leveling mortar, with a flowability of over 130mm within 30 minutes, meeting
the requirements for large-area construction.
Crack Resistance and Wear Resistance
The polymer powder improved the flexibility of the mortar, reducing microcracks during hydration and enhancing crack resistance and wear resistance.
Adhesive Strength
The modified self-leveling mortar achieved an adhesive strength of 1.65MPa, far exceeding
industry standards and suitable for various substrates.
Surface Quality
The finished floor surface was smooth and crack-free, with no visible pores or cracks, providing
an excellent decorative finish.
Construction Results
After actual construction, the floor achieved high flatness, with no hollow sounds or cracking. The wear resistance and stain resistance were significantly improved. The construction team reported that the self-leveling mortar with added polymer powder had excellent construction performance, high efficiency, and low maintenance costs.
Conclusion
The application of redispersible polymer powder in self-leveling mortar effectively enhanced the flowability and construction performance of the mortar while improving crack resistance, wear resistance, and adhesive strength. This modified self-leveling mortar meets the requirements for high-quality floor construction and is suitable for commercial buildings, industrial plants, and other locations with high floor performance demands.
