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Section Contents Page

11 Levelling of substrates 347

11.1 Self-levelling materials 351

11.1.1 Jointless ambiento® floor 356

11.2 Thixotropic materials 358

11.3 Sopro product systems for sustainable construction

362

349

Levelling of substrates 11

Substrate preparation

Preparation matrix

The pretreatment of substrates is necessary to ensure the optimum bonding of levelling compounds. Special primers are available for preparing both absorbent and non-absorbent substrates. The levelling compound is applied after the priming coat has dried. Alternatively, a bonding

emulsion may be used in many cases to allow subsequent wet-on-wet application of the levelling compound.

Fast-track (without drying time)

Wet-on-wet After drying

Sopro HE 449 Sopro GD 749 Sopro HPS 673

Substrates Undiluted Diluted

Non-absorbent:

Old ceramic coverings • •

Terrazzo • •

Firmly adhering lacquer/varnish • •

Mastic asphalt tiles/screeds •

Natural/cast stone units • •

Non-absorbent concrete • •

Adhesive residue •

Absorbent:

Cement screeds • •

Absorbent concrete • •

Calcium sulphate screeds •*

Board subfloors •

Special solutions:

Magnesite screeds Sopro EPG 522 epoxy primer (thickly applied), blinded with silica sand

Oil-contaminated concrete/screed Sopro ESG 868 epoxy primer sealer (thickly applied), blinded with silica sand

* Please observe current versions of technical product information.

350

Levelling of substrates11

Substrate preparation

Sopro GD 749Light-blue, solvent-free, synthetic resin primer for high- or variable-suction substrates. For pretreatment of cement screeds, calcium sulphate screeds, board subfloors, gypsum plasterboard and gypsum fibreboard, lime/cement render and gypsum plasterwork. Water-thinnable when applied to high-suction substrates. Use Sopro GD 749 primer only in concentrated form with gypsum-bound substrates or where overcoated by Sopro flow-applied floor-levelling compound.*

Sopro EPG 522Solvent-free, unpigmented, two-component liquid epoxy resin. Applied as primer to stabilize friable mineral substrates and as adhesion promoter on smooth substrates, e.g. metal, mastic asphalt and existing coatings. Used to provide seal and prevent capillary action in cementitious substrates, to fill cracks, to grout joints around channels and floor drains and to produce capillary-breaking joints. May be applied as epoxy mortar where extended with Sopro KQS 607 crystal quartz sand or Sopro QS 511 coarse silica sand. Resistant to water, sea water, wastewater/sewage, alkaline solutions, diluted acids, salt solutions, mineral oils, fuels and lubricants. Used to seal capillaries in damp cementitious substrates to speed up laying of parquet, PVC etc.

Sopro ESG 868Solvent-free, two-component epoxy resin barrier coat for substrate preparation, particularly suitable for application to freshly laid and/or damp screeds. May be applied to oily concrete substrates where previously cleaned. Excels by outstanding wetting and adhesive properties on damp concrete/screed substrates and reduces risk of osmotic blistering. Provides barrier against rising damp. Resistant to water, sea water, wastewater/sewage, diluted acids, alkaline solutions, mineral oils, fuels and lubricants.

Sopro HPS 673Special light-grey, polymer dispersion-based, silica sand-modified, solvent-free primer, applied as bonding layer to impervious, smooth and non-absorbent substrates prior to tile laying. Particularly suitable for laying on existing ceramic coverings. Also used as bonding primer on timber, mastic asphalt or magnesite (magnesium oxychloride) screeds and existing firmly adhering adhesive residue, lacquers/varnishes and PVC coverings.

Sopro HE 449Synthetic resin dispersion used as bonding layer for mineral surface fillers and plasters/renders (e.g. Sopro FS 15 550 floor-levelling compound). For wet-on-wet application. For modification of mortars, screeds and slurries.Note: For wet-on-wet application with Sopro HE 449, the amount of bonding emulsion applied in one operation should be such that it does not dry out prior to overcoating.

Specialist products:

* Please observe current versions of technical product information.

351

Levelling of substrates 11.1

Self-levelling materials

Not uncommonly, substrates that are to receive a ceramic, natural stone or other covering fail to exhibit the required degree of levelness, particularly for large-format tiling.This necessitates the application of a levelling coat prior to tiling. The correct choice of levelling compound is governed by the following parameters:

1. Overall coat thickness to be applied

2. Material and nature of substrate

3. Laying to falls or production of plane, horizontal surface (self-levelling compounds may be used where no falls are required)

Strong substrate

FS 5® 5495 mm

FS 15® 55040 mm

Rapidur® FE 67870 mm

Sopro FS 15 550 Up to 40 mm thickness

Sopro Rapidur® FE 678 20 – 70 mm thickness

Application of Sopro FS 15 550 floor-levelling compound in preparation for installation of large-format tiles using thin-bed method.

Sopro concept for self-levelling surface fillers and screeds:

Levelling coat thicknessesProperties:

• For floors• For indoor use• Self-levelling• Excellent workability and flow

properties due to superplasticizing admixture, coupled with outstanding hardened mortar properties thanks to Sopro Mikrodur® technology

• Rapid-set, i.e. walkable after 2 – 3 hours

• Castor chair resistant• Suitable for floor heating systems• Suitable for machine application• Low-chromate to Regulation (EC)

No 1907/2006, Annex XVII

Sopro FS 5 549 Up to 5 mm thickness

352

Levelling of substrates11.1


Sopro HF-S 563 4 – 40 mm

A levelling compound which combines high final strength with abrasion resistance offers a prime solution for facility types and occupancies requiring only a hardwearing surface without any additional floor finish.

Sopro HF-S 563, a rapid-set, hydraulic floor-levelling compound based on Sopro Mikrodur® technology, is suitable for the production of industrial flooring (warehousing) or for spaces where smooth, dense, homogeneous, non-absorbent surfaces are required for their aesthetic/architectural effect (e.g. in shops).

Straightforward machine application of Sopro HF-S 563 high-strength floor-levelling compound.

Placing of Sopro HE 449 bonding emulsion for subsequent wet-on-wet application of Sopro HF-S 563 high-strength floor-levelling compound.

Plane, level floor surface with high abrasion resistance after setting.

Coat thickness range Sopro HF-S 563

Product recommendation

Abrasion-resistant floor-levelling compound (Sopro HF-S 563)

4 – 40 mm

353



SoproDur® HF-L 513

Sopro HF-S 563

System composition: Sopro HF-S 563/SoproDur® HF-L 513

SoproDur® HF-L 513 Component A

SoproDur® HF-L 513 Component B

SoproDur® HF-L 513 in refuse room, in conjunction with wall tiling.

Wide variety of surface effects possible with SoproDur® HF-L 513.

SoproDur® HF-L 513 for straightforward treatment and improvement of garage and basement spaces.

If required, Sopro HF-S 563 high-strength floor-levelling compound may be finished with a SoproDur® HF-L 513 high-strength epoxy protective coat. The surface appearance may be enhanced by blinding with silica sand, colour chips etc.

Product recommendation:

Reaction resin surface coating (SoproDur® HF-L 513)

Structural con-crete

354


1–30 mm

Pumpable, flow-applied, rapid-set, alpha-hemihydrate-based floor-levelling compound. Used to level out calcium sulphate screeds and to produce smooth, level, unbroken substrates for subsequent laying of coverings such as ceramic tiles, natural stone units, textile and elastic flooring.

• For floors• For indoor use• Coat thickness: 1 – 30 mm; for thicknesses upwards of

10 mm may be extended with 0 – 2 mm graded sand• Working life: approx. 40 minutes• Walkable: after approx. 3 hours• Ready to receive floor covering: for coat thicknesses up

to 10 mm, after approx. 24 – 36 hours• Suitable for floor heating systems

Floor-levelling compound specially tailored to calcium sulphate screeds to prevent stress accumulation in floor construction.

Calcium sulphate-based substrates and mastic asphalt screeds


Sopro AFS 561 1 – 30 mm

Pouring of Sopro AFS 561 anhydrite floor-levelling compound

Calcium sulphate (anhydrite) screeds require a specially tailored levelling compound to eliminate the risk of later adhesion failure due to ettringite formation (see Section 7.3). To ensure trouble-free adhesion, this compound also needs to exhibit similar properties in terms of shrinkage and coefficient of expansion.


Coat thickness range Sopro AFS 561

1 – 30 mm coat thickness

Sopro AFS 561Calcium sulphate (anhydrite) screed

Mastic asphalt screeds:The suitability of cementitious surface fillers for levelling out mastic asphalt screeds is extremely limited (max. 5 mm coat thicknesses) due to mastic asphalt's thermoplastic properties and brittle behaviour after cooling. Due to its very low internal stress development, Sopro AFS 561 anhydrite floor-levelling compound may be readily used in up to 30 mm coat thicknesses for evening out mastic asphalt screeds. The screed should be pretreated with Sopro HPS 673 special primer in such cases. After the Sopro AFS 561 compound has dried, it should be sealed off with Sopro EPG 522 epoxy primer.

355


Timber substrates

Flexible, flow-applied, self-levelling, rapid-set, cementitious, fibre-reinforced surface filler used to even out irregularities in timber and mineral substrates, especially on refurbishment/renovation contracts.

• For floors• For indoor use• Coat thickness: 3 – 40 mm; for thicknesses upwards of

20 mm must be extended with 0 – 4 mm graded sand• Flexible• Working life: 20 – 30 minutes• Walkable: after approx. 2 hours• Ready to receive floor covering: for coat thicknesses up

to 10 mm, after approx. 24 hours• Low-chromate to Regulation (EC) No 1907/2006, Annex

XVII

Sopro FAS 551 fibre-reinforced self-levelling filler is used to create plane, level surfaces on unstable and uneven timber substrates (e.g. sagging timber floorboards).


Sopro FAS 5513 – 25 mm


Spreading of Sopro FAS 551 fibre-reinforced self-levelling filler over timber floorboards and air release using spiked roller.

3–25 mm

Thin, fibre-reinforced levelling coat on timber floorboards.

Warped, uneven, high-stress timber substrate

356

Levelling of substrates11.1.1

Jointless ambiento® floor

High-strength, cementitious floor-levelling compounds are also available in premixed colours for floors subject to aesthetic as well as technical demands (e.g. in shops).Sopro DFS ambiento® floor is a designer floor topping for the production of attractively coloured, jointless, high-strength floor finishes.


Sopro DFS ambiento® floor in a clothes shop.

Sopro DFS ambiento® floor is available in three colours:

silver

flannel grey

white

The floor finishes created with Sopro DFS ambiento® floor are directly usable. The product lends itself to versatile use in the design of flooring for a wide variety of spaces.

Given that the resulting floor finishes are unique creations and vary according to project-specific conditions, all mock-ups/sampling must be performed on the relevant site!

Other colours are available on request, subject to minimum order quantity.

Surface pretreated with Sopro EPG 522 epoxy primer and blinded to excess with sand.

Substrate preparation, where required, by grinding/scabbling.

Application

For technical reasons, the colours shown here may diverge from those of the fully cured material.

357

Levelling of substrates 11.1.1

Preparation for mixing of Sopro DFS ambiento® floor.

Suitable Dr. Schnell/Dr. Schutz products can be used to protect the surface of the Sopro DFS ambiento® floor topping.

Sopro DFS ambiento® floor can be spread and compacted using a spiked roller.

Sopro DFS ambiento® floor spread across surface with squeegee.

Sopro ambiento® floor sets and is walkable after only a few hours.

Sopro EPG 522 epoxy primer blinded to excess with sand.

358


3 mm

30 mm

Sopro RAM 3® 454 renovation and levelling mortar/Sopro AMT 468 levelling mortar with trass

cement screedConcrete or

Apart from producing plane, horizontal surfaces (e.g. in dwelling spaces), levelling coats sometimes have to be laid to falls, especially in areas exposed to water or where floor drains are installed (e.g. on balconies or in commercial facilities).

Hence the need for mouldable, sag-resistant, thixotropic fillers to create surface gradients or even out irregularities in wall areas.

Levelling coat laid to falls on concrete or screed.

Sopro RAM 3 454 renovation and levelling mortar laid to falls on cantilevered balcony slab.

Grey, sag-resistant, rapid-set, cementitious surface filler applied to walls and floors for patching and smoothing concrete, plasterwork, masonry and screed surfaces. Particularly suitable as levelling plaster/render on wall areas with various substrates (different types of masonry unit, concrete etc.) due to its stress-accommodating properties.

• For walls and floors• For indoor and outdoor use• Trass-bearing• Coat thickness: 2 – 30 mm• Working life: approx. 45 minutes• Walkable: after approx. 6 hours• Low-chromate to Regulation (EC)


Universal, sag-resistant, rapid-set, cementitious render and surface filler for rapid smoothing, patching and rendering of wall and floor surfaces. For application to mineral substrates, e.g. concrete, aerated concrete and masonry. Excellent workability and mouldability. Ideal for renovation and refurbishment. Ready for tiling after only 2 hours. Suitable for use in damp and wet spaces, and on balconies and patios. The mortar's rapid strength development allows early removal of uneven patches in filler coat using plasterer's lattice plane.

• Coat thickness: 3 – 30 mm• For walls, floors and ceilings• For indoor and outdoor use• Working life: approx. 20 minutes• Walkable: after approx. 1.5 hours• Meets DIN EN 998-1 requirements,

strength class CS IV• Low-chromate to Regulation (EC)


Thixotropic materials

Sopro AMT 468ready for tiling after approx. 12 hours

Sopro RAM 3 454ready for tiling after approx. 2 hours

Cutaway section of levelling coat to falls


Mortar laid to falls for ramp, e.g. at garage door

For surfaces exposed to constant and fluctuating moisture migration, provision should be made for the incorporation of a waterproof membrane. This applies for both products!

359


Universal, sag-resistant, rapid-set, cementitious render and surface filler for rapid smoothing, patching and rendering of wall and floor surfaces. For application to mineral substrates, e.g. concrete, aerated concrete and masonry. Excellent workability and mouldability. Ideal for renovation and refurbishment. Ready for tiling after only 2 hours. Suitable for use in damp and wet spaces, and on balconies and patios. The mortar's rapid strength development allows early removal of uneven patches in filler coat using plasterer's lattice plane.

• Coat thickness: 3 – 30 mm• For walls, floors and ceilings• For indoor and outdoor use• Working life: approx. 20 minutes• Walkable: after approx. 1.5 hours• Meets DIN EN 998-1 requirements,

strength class CS IV• Low-chromate to Regulation (EC)


Sopro RAM 3 454ready for tiling after approx. 2 hours

Particularly on refurbishment contracts, it is often necessary to even out walls or to patch hollows, chips or spalls prior to thin-bed fixing of a new ceramic finish.

Use of Sopro RAM 3 454 renovation and levelling mortar is recommended to minimize waiting times prior to installation of the covering on the levelled substrate.

Levelling of masonry with Sopro RAM 3 454 renovation and levelling mortar prior to thin-bed tiling

Levelling of masonry with Sopro RAM 3 454 renovation and levelling mortar prior to thin-bed tiling



Masonry

Sopro GD 749

Sopro RAM 3® 454

Waterproof membrane

Tile

Thin-bed tile adhesive

min. 2 – 3 mm

max. 30 mm

360


Swimming pool construction

Applications where reinforced-concrete swimming pools need levelling, coating or modelling (children's pools) necessitate the use of custom-developed, special-purpose, cementitious, hydrated lime-free renders and surface fillers.

Sopro SBP 474 swimming pool render was specially developed for these applications and meets the requirements of the ZDB (Federation of the German Construction Industry) data sheet “Swimming pool construction". The rapid-setting properties of Sopro SBP 474 also allow the rapid continuation of works (i.e. with waterproofing and tiling operations).

Sopro SBP 474 is easily workable by hand.

Sopro SBP 474 is easy to rule off with an aluminium straightedge.

The large-scale application of Sopro SBP 474 can also be carried out by machine.

Sopro SBP 474 allows easy modelling and moulding of pool areas using a template.


Sopro SBP 474

PCC-mortar without

hydrated lime

PCC-mortar without

hydrated lime

»Swim

m

ing pool constructio

n«

!!

Com

plies with ZDB data sheet

361


Special applications

Maintenance repair work is often required for surfaces subject to high mechanical loads (e.g. heavy-goods vehicles or fork-lift trucks). This necessitates the use of mortars with extra-high strength and chemical resistance, e.g. for the refurbishment of ramps.

Fixing of pool edge units using Sopro EE 771 epoxy mortar.

Heavy-duty areas, e.g. ramp.

High-strength Sopro EE 771 epoxy mortar coating to accommodate high moving point loads.

Sopro EE 771 epoxy mortar excels by its:• exceptionally high final strength• strong interlock with substrate• chemical resistance• straightforward application

Sopro EE 771

Floor drain fixed with Sopro EE 771



1 Waterproof membrane

2 Flexible thin-bed tile adhesive

3 Sopro EE 771 epoxy mortar

4 Tile grout, e.g. Sopro TF

5 Elastic joint sealant, e.g. Sopro Sanitary Silicone

B Concrete

BA Floor drain

D Insulation

E Screed

F Tile

2 F 1 D BA 5 3 E 4 B

Note: Sopro EE 771 can also be used to produce thin-layer floating screed constructions such as those commonly needed for barrier-free shower areas. See also Section 3.

362


RAM 3 454 renovation and levelling mortarDGNB: Top quality level 4, Line 8**

Sopro FS 5 549 floor-levelling compoundDGNB: Top quality level 4, Line 8**

Sopro HF-S 563 high-strength levelling compoundDGNB: Top quality level 4, Line 8**

Sopro FAS 551fibre-reinforced self-levelling fillerDGNB: Top quality level 4, Line 8**

SBP 474 swimming pool renderDGNB: Top quality level 4, Line 8**

Sopro AFS 561anhydrite levelling compoundDGNB: Top quality level 4, Line 8**

Low-emission floor-levelling compounds* – flow-applied

Low-emission floor-levelling compounds* – thixotropic

Schematic system composition

Sopro product systems forsustainable construction

* For details of all relevant Sopro products, please consult our sustainability brochure.** Rating under German Sustainable Building Council (DGNB) quality certification scheme, Criterion "ENV1.2 Local Environmental Impact" (2015 version).

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