Industrial screeds are vital for flooring systems to last and perform well. They create the groundwork for the floor finish by providing a flat, solid, and seamless finish.
Their design makes them ideal for use in business spaces, such as factories, workshops, and factories, where they can withstand heavy loads, significant foot traffic, and handling hazardous material.
Depending on your needs, you may pick flooring such as concrete floor, cementitious or traditional screed, industrial screeds that dry quickly, are heavy duty or are resistant to wear and moisture content.
Knowing the various kinds of screed and how they are used is essential for determining the right one for every industrial project.
What is an Industrial Floor Screed?
Industrial floor screed is a specialist building material that lays a level, smooth base for various flooring types. Screeds typically fall on top of a subfloor to guarantee a solid and even surface. They are made of cement, sand, and various additives.
These levelling screeds must endure enormous loads and wear and tear to function properly in businesses. They can also withstand the constant foot traffic, chemical exposure, heating and heavy machinery operation in industrial settings. An industrial floor screed’s correct application is critical to the flooring system’s function and endurance.
Types of Industrial Floor Screed
Pump Screed
One kind of floor screed that is applied with the use of specialized pumping equipment is an industrial pump screed. Using this technique, the screed material may be distributed more effectively and uniformly over wide regions. The screed mix typically comes to the site in liquid form and comprises cement, sand, and several additives.
Once laid into position, the screed is leveled and smoothed to produce a level, long-lasting and uneven surface. Pump screeds are very useful in industrial environments because they can cover vast areas rapidly and uniformly, saving money on labor and installation time.
Benefits
- Efficiency: Compared to traditional methods, pump screeds may be applied fast, thus fast drying reduces installation time.
- Uniform Application: This improves the overall quality of the floor by guaranteeing a constant, flat surface across large regions.
- Lower Labour Costs: Because of the pumping process’ efficiency, less intensive physical labor is required.
- Durability: Builds a solid, resilient base to sustain intensive industrial use.
- Better Quality Control: A regulated application process reduces the possibility of human error, producing a more dependable finish.
Drawbacks
- Specialized Equipment: Needs specialized pumping equipment, which can be expensive to buy or rent.
- Initial Cost: Because more equipment and materials are needed, the initial cost is higher than with specific typical screeding techniques.
Sand Cement Screed
A classic industrial floor screed is a sand-cement screed, which is composed of a combination of sand, cement, and water. The ultimate floor finish is applied on a level and smooth surface created by using this blend on a prepared substrate.
Screeds made of sand and cement are typical in industrial settings because of their strength and the weight that they can sustain. Depending on the project’s size, the screed is mixed on-site and applied manually or with powered equipment. For the screed to reach its maximum endurance and durability after application, it must cure correctly.
Benefits
- Long Lasting: Sand cement screeds are long-lasting because they create a firm, durable surface that can withstand heavy foot traffic and severe industrial use.
- Multi-Use: Works well with vinyl, epoxy coatings, and tile styles.
- Save Money: It’s an excellent alternative for big-budget jobs because it’s usually cheaper than other current screening technologies.
- Very Easy to Apply: Only essential hand tools for mixing and application on-site are required.
- Established Record: This conventional approach has been used for years, offering a dependable and tried-and-true remedy for industrial facilities’ flooring requirements.
Drawbacks
- Installation: The installation of the final floor finish may be delayed due to the long curing period required by sand cement screeds.
- Application: Manual mixing and application can be laborious, especially when dealing with big areas.
- Possibility of Cracking: If sand cement screeds are not properly mixed or applied, the floor’s stability may be compromised, raising the possibility of splitting.
- Moisture content: Problems like contraction and cracking may arise if the moisture content is not closely supervised during the mixing and curing procedures.
Resin Floor Screed
An industrial resin floor screed is a high-performance flooring system consisting of aggregates, synthetic resins, and hardening agents. This type of screed is unique because of its long life lifespan, smooth surface, and superior chemical resistance. When used as a solution, it dries into a robust surface resistant to abrasion from heavy machinery and working environments.
Many resin screeds, including methyl methacrylate, also known as (MMA), epoxy, and polyurethane, have unique properties that make them perfect for various industrial uses. These screeds are ideal for spotless places, like food processing industries, pharmaceutical facilities, and industrial kitchens.
Benefits
- Longevity: Resin screeds are resilient and robust, so they can withstand much foot traffic and heavy machinery without getting damaged.
- Resistance: Because of their exceptional resistance to chemicals, oils, and solvents are ideal for settings where these substances are commonly employed.
- Effortless Finish: The application minimizes joints and cracks, which helps keep surfaces clean and germs-free.
- Quick Curing: Some varieties, such as MMA resin screeds, have fast curing times, which means less downtime when installing them.
- Versatility: The wide range of color grade and finishes makes aesthetic versatility, suitable for use and incorporating safety marks or branding possible.
Drawbacks
- Cost: Resin screeds are more costly to purchase and install than conventional screeds.
- Surface preparation: Proper adhesion and performance necessitate thorough surface preparation, which can increase the project’s complexity and duration.
- Need for Skilled labor: Skilled labor and specialized equipment are typically needed for specialized applications, which might increase the overall cost and complexity of the project.
Bonded Screed
Industrial floor screeds can be bonded directly to a prepared substrate, forming a strong bond between the two. This technique uses a cement slurry or other bonding agent to ensure the screed sticks to the base. Usually ranging from 10 to 40 mm in thickness, bonded screeds are noticeably thinner than other varieties.
They are perfect for places that need a robust and long-lasting surface but want to raise the floor level sparingly. Because of this, bonded screeds are a standard option in commercial and industrial spaces with limited floor height and require a rigid, long-lasting surface.
Benefits
- Load-bearing capacity: The bonding agent strengthens the screed’s attachment to the substrate, increasing the latter’s load-bearing capacity and the former’s longevity.
- Less installation cost: Applications with a thin profile use less material, which lowers installation costs and makes them suitable for spaces with limited ceiling height.
- Longevity: Designed for demanding tasks, this material is perfect for industrial spaces that experience heavy machinery and foot traffic.
- Economical: Since less floor coverings material is used, the cost is usually lower compared to applications with thicker screeds.
- Reduced Time Required for Installation: Compared to floating or unbonded screeds, the thinner application may result in shorter installation timeframes.
Drawbacks
- Surface Preparation: The substrate must be meticulously prepared to guarantee good bonding and performance.
- Moisture sensitivity: To avoid problems with adherence and longevity for a range of floor, the substrate should be dry and devoid of impurities, known as moisture sensitivity.
- Inadequate Thickness: Do not use this screed in any situation requiring a thicker layer of insulation or extra strength.
Unbonded screed
Industrial floor screeds can be either directly attached to the substrate or spread over a separating layer, the latter of which is usually a membrane. To keep the screed unaffected by substrate movement, a damp-proof membrane (DPM) or slip sheet might serve as this dividing layer.
The unbonded screed is often thicker for sufficient strength and longevity, averaging 50-100 mm. This approach is commonly employed when there is a problem with the substrate’s compliance owing to moisture, contaminants, or any other reason.
Benefits
- Controlling Moisture: The separating covering can prevent expanding dampness and other humidity-related problems by acting as a moisture barrier, protecting the screed.
- Flexibility: Cracking due to substrate mobility or thermal expansion can be mitigated by providing some movement between the screed and the substrate, which can be accomplished through flexibility.
- Suitable for Poor Substrates: Can be applied to surfaces that are usually unsuitable for bonded screeds.
- Solid and long-lasting surface: The correct laying of unbonded screeds generates a solid and long-lasting surface, thus rendering them ideal for use in business environments.
- Cost-Effective Under Some Conditions: Unbonded screeds provide an acceptable substitute for bonded screeds when substrate preparation is too expensive or time-consuming.
Drawbacks
- Thickness: Unbonded screeds must be thicker than bonded screeds to maintain durability and strength. This makes them less suited for some projects since they elevate floor levels.
- Improper installation: Screed performance can be compromised by excessive movement or improper installation despite its design to permit movement.
FAQ’s
What options were there for industrial floor screeds?
Several popular kinds of screeds exist, such as bonded, unbonded, pump, sand cement, and resin. Due to their specific characteristics, various types are ideal for multiple business uses.
When comparing bonded and unbonded screeds, what are the key differences?
Unbonded screeds are placed over a barrier layer, like a membrane, whereas joined screeds are directly adhered to the backing material with a bonding agent. Unbonded screeds are employed when the substrate might not be compatible with bonding, in contrast to bonded screeds, which are lighter and work better with solid substrates.
For an industrial floor, what thickness screed is recommended?
The screed’s nature and intended use determine its thickness. Unbonded screeds are usually 50-100 mm thick for stability and longevity. However, bonded screeds can be as thin as 10-40 mm.
Is the cost of resin screeds higher than that of regular screeds?
The unique features of resin screeds and the need for expert application typically cause them to have higher material and installation costs. However, their chemical resistance, smooth polish, and exceptional longevity are unmatched.
Conclusion
If you want a level, long-lasting surface that will withstand the wear and tear of the workplace, you need industrial floor screeds. Unbonded screeds provide flexibility and moisture control in less stable situations, whereas bonded screeds give a strong, thin layer on top of a stable substrate. Choosing the suitable screed is necessary for industrial flooring projects to ensure long-lasting performance and efficiency. Each type of screed has its own set of pros and cons. Proper installation by knowledgeable personnel is the key to achieving the benefits and reducing potential concerns.