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SELF-LEVELLING ROUGH FLOOR
(from 25 mm to 60 mm)
UNDER TERRACOTTA, FLOOR COVERING AND WOOD FLOORING, RECOMMENDED FOR FLOOR HEATING SYSTEMS
FOR INTERNAL USE
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| AVAL KN 20 is a self-levelling anhydrite jointless floor suitable for mechanical and manual rough floor making under terracotta, wood flooring and various floor covering. AVAL KN 20 is suitable for all kinds of dry residential buildings, public buildings and other places provided that its parameters comply with utilisation and strength properties of such locations. AVAL KN 20 can be used for rough floor in the following arrangements: connected with existing substrate (minimum bed thickness - 25 mm), on the separating layer (minimum bed thickness - 30 mm), floating (minimum layer thickness - 35 mm) or in floor heating systems (minimum layer thickness over heating elements - 25 mm). It is suitable only for interior use. |
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| AVAL KN 20 is a ready-made dry mixture based on high-quality anhydrite. It is very convenient and easy to use. It has a self-levelling ability, can be easily and quickly poured on substrates using machines equipped with worm pumps. This ensures efficient application and lower labour costs. AVAL KN 20 shows very good strength properties and after setting, it is virtually a non-contracting material. It is recommended for floor heating systems due to its good heat conductivity and good insulation of heating pipes. |
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| The method of preparation depends on the arrangement in which AVAL KN 20 is to be used. Detailed instructions below. In any case, the substrate should be stable and structurally sound and, due to the risk of underlayment outflow, should have a tank-like appearance. All steel elements that are in contact with the rough floor should be protected against corrosion. Intermediate expansion joints are not necessary in case of pouring of jointless floor over a surface smaller than 50 m2 where the diagonal is less than 10 m. However, separate the jointless floor from walls and other elements within the pouring area using expansion tapes or thin strips of foamed polystyrene. |
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| In case of mechanical pouring, pour a dry mixture to a basket in a mixing-pumping unit and appropriately set the fixed level of dosed water that ensures correct consistency of the mix flowing out from a hose. In case of manual pouring, prepare it by pouring dry mortar into a container with suitable amount of water (in the ratio of 4.5÷5.1 l of water for 30 kg of container) and mix until homogenous. Do it mechanically; a drill with a mixer is recommended. The mix is ready to use immediately after mixing. It maintains its properties for ca. 40-50 minutes. To check consistency, pour out the mortar from a 1 l container onto even non-absorptive substrate (for example - foil). The mortar should then form a `patch` of ca. 45-50 cm in diameter. |
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The mix is poured out mechanically using a mixing-pumping unit with continuous flow proportioning of water. It can be poured manually, but only on surfaces divided into 10÷15 m2 technological fields. Before starting work it is necessary to set the planned thickness of the rough floor (on the walls and in the pour area) in the rooms. This can be done using for example a level and portable height bench-marks. Pour the prepared mortar evenly and continuously up to the desired height, avoiding gaps. The assumed technological field should be completed in ca. 1 hour. Right after pouring in each field, de-aerate the mix using, for example, a de-aerating roller or a brush with long hard horsehair, moving the brush in shaking manner along and across the poured surface. Then self-levelling of the mix occurs automatically. Constantly check the mixing degree and consistency. During first two days of maturation of the bonded floor, do not expose the floor to direct sunlight and draughts, and provide proper ventilation of rooms. If white tarnish has appeared on the surface, remove it mechanically by grinding, and then vacuum the whole surface. Grinding accelerates the drying process. The drying time of anhydrite bonded floor depends on the layer thickness and also thermal conditions and humidity in a given room. Depending on the maturation conditions, humidity, type of floor covering and its permeability, floor covering operations can start on average after 3÷4 weeks. Before commencement of work, it is recommended to dry bonded floor surface thoroughly and prime it with AVAL KN 97. The information comprises basic instructions of product application and does not relieve users of responsibility for work in accordance with good construction practice and OHS regulations.
Bonded jointless floor
It is characterised by direct and whole-surface connection with the substrate. AVAL KN 20 can be applied on any mature mineral substrate, except for substrates with magnesia binder. The substrate should be dry and free from anything that may impede adhesion, in particular dust, dirt, lime, oil, fat, wax, bitumen, paint, etc. Mechanically remove loose elements and parts of substrate of poor strength. If necessary, the use of AVAL KN 97 priming emulsion is recommended to reduce the substrate`s absorption. The emulsion, among others, prevents air bubble formation on the surface. AVAL KN 20 as connected jointless floor is not suitable for rooms in which humidity penetration is possible. The minimum thickness of the underlayment is 25 mm.
Unbonded floor on the separation layer
It is prepared on very weak, absorptive or oiled mineral substrates or on other substrates that do not provide appropriate adhesion. AVAL KN 20 should be placed on a separation layer (for example one made of 0.2 mm thick polyethylene foil). In case of substrates which are exposed to moisture, a vapour-resistant or damp insulation placed on the substrate may serve as the separation layer. The insulation should be placed tightly without creases and folded onto the walls (onto the expansion joint strips), at least up to the rough floor height. The minimum layer thickness is 30 mm.
Floating unbonded floor
AVAL KN 20 can be placed on thermal or acoustic insulation layers, for example, made of foamed polystyrene of at least EPS 100-038 grade, hardened floor panels made of mineral wool or other materials fit for this purpose. Pay special attention to accurate and even distribution of all the materials applied on the surface. The insulation should be placed tightly and horizontally on the substrate and the boards should be laid with offset edges. In order to level the substrate, substance such as dry sand may be used under the hard boards. The insulation must be always protected against contact with the rough floor being made, with the help of tight separation layer folded onto the walls (for example one layer of 0.1 mm thick polyethylene foil or plastic coated paper). The unbonded floor can in no place have contact with the rough floor, walls or installations. If the compressibility of the insulation exceeds 5 mm or greater loads are anticipated, the thickness of the unbonded floor should be increased correspondingly, or the unbonded floor should be made as reinforced floor. The minimum layer thickness is 35 mm.
Unbonded floor in the floor heating system
The installation should be checked and fastened properly. In the case of water heating, the heating pipes should be filled with water before pouring AVAL KN 20. The unbonded floor should be made as two layers (in order to prevent floating of pipes); the first layer should be poured up to the upper edge of heating pipes, and the height of the second layer should be at least 25 mm above the pipes. The second layer of the underlayment can be made after initial setting of the first layer when it can be used (after min. 24 hours). If the installation has been prepared and mounted properly, it is allowed to make the unbonded floor as a single layer. In order to vent the underlayment, it is recommended to use a brush with long hard horsehair. In addition, respect the specifications of the technical project as well as recommendations provided by the heating system manufacturer. Progressive heating of the unbonded floor (temperature increase by max. 3°C in 24 hours) can begin not earlier than 7 days after pouring the underlayment, and full heating is allowed after 28 days. |
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| On average 20 kg of the mortar is used for 1 m2 for each 10 mm of the layer. |
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| A drill with a mixer (manual pouring), mixing-pumping unit (mechanical pouring), brush with long hard horsehair or de-aerating roller , height benchmarks. Wash the tools with clean water directly after use. |
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Paper bags: 30 kg
Pallet: 1080 kg in 30 kg bags |
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| Keep dry. Store and transport dry on pallets in tightly closed bags. Shelf life is 6 months from the production date on the packaging. |
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| Alkaline reaction with water – protect eyes and skin. In case of direct contact with eyes, seek medical attention. |
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Mixing proportions
ca. 0.15÷0.17 l of water for 1 kg of mortar
ca. 4.50÷5.10 l of water for 30 kg of mortar
Pot life - ca. 45 minutes
Mortar preparation temperature – from +5°C to +25°C
Substrate and ambient temperature – from +5°C to +25°C
Rough floor use - after ca. 2 days
Complete setting and drying – min. 3 weeks
Floor covering - rough floor humidity not greater than 1.5%
(in case of non-permeable and wood-based floor covering,
observe recommendations of adhesive and covering manufacturer)
Dry mortar density – 1.4 kg/dm3
Max. aggregate diameter – 0.8 mm
Min. layer thickness - 25 mm
Max. layer thickness - 60 mm
Content of soluble chromium (VI)
in ready-to-use mix - ≤0.0002%
Reaction to fire - A1fl class
pH >7
Compressive strength - C16(min. 16 N/mm2)
Flexural strength – F5 (min. 5 N/mm2)
Corrosive substance release - CA
Water and water vapour permeability – NPD
Sound insulation - NPD
Sound absorbance - NPD
Thermal resistance - NPD
Chemical resistance - NPD |
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