Granolithic concrete flooring is a type of flooring that is ideal for heavy engineering factories, workshops, garages, warehouses, and other similar facilities. This type of flooring is made using a rich concrete mix, which is specially designed to withstand heavy usage and foot traffic.
The concrete mix used in granolithic flooring contains aggregate with specific characteristics. This aggregate is carefully selected for its high hardness, surface texture, and particle shape. These features ensure that the flooring is durable, resistant to wear and tear, and can withstand heavy machinery and equipment without cracking or crumbling.
Granolithic flooring is a popular choice for industrial and commercial buildings due to its strength and durability. It is designed to withstand harsh working conditions, including exposure to chemicals, oil spills, and heavy loads. This flooring option is also low maintenance, making it a cost-effective choice for many businesses.
Overall, granolithic concrete flooring is an excellent choice for those looking for a strong and durable flooring solution that can withstand heavy usage and foot traffic. Its carefully selected aggregate and rich concrete mix make it an ideal option for a wide range of industrial and commercial applications.
Fig 1: Granolithic Concrete Flooring.
Granolithic concrete is a popular choice for flooring applications where high abrasion resistance is required, especially in areas where the combination of abrasion and impact is likely to be severe. This makes it an ideal choice for industrial and commercial facilities that experience heavy foot and machinery traffic.
There are two different methods for laying granolithic concrete flooring. The first is the monolithic method, where the topping layer is laid within three hours of the base concrete being laid. This method is preferred when a seamless finish is desired and when time is of the essence.
The second method is the non-monolithic method, where the topping layer is laid after the base concrete has set. This method is preferred when a decorative finish is desired, as it allows for greater flexibility in the design and application of the topping layer.
Regardless of the method used, granolithic concrete flooring is a reliable and durable flooring option for industrial and commercial facilities. Its high abrasion resistance ensures that it can withstand heavy usage and foot traffic while maintaining its integrity and appearance.
Material for Granolithic Concrete Flooring
1. Aggregate
The aggregates utilized for laying concrete flooring should belong to one or more of the following groups: Granite, Basalt, Trap, and Quartzite. Each country may have its own requirements that these aggregates must conform to. Additionally, the crushing value of the aggregates should not exceed 30 percent.
2. Abrasives
To enhance the ability of a floor topping to resist abrasion, one can include materials with high abrasion resistance in the mix. These materials may either be metallic or non-metallic in nature. By doing so, the floor topping can withstand the wear and tear caused by abrasive forces and maintain its integrity and durability over time.
When selecting materials to incorporate into the floor topping mix, it is important to consider their properties, including their level of abrasion resistance. The higher the abrasion resistance, the better the material will perform in withstanding abrasive forces. Metallic materials, such as steel or iron, are known for their high abrasion resistance and can be added to the mix to reinforce the floor topping.
Non-metallic materials, on the other hand, also offer high levels of abrasion resistance and can be used as an alternative to metallic materials. Some examples of non-metallic materials with high abrasion resistance include ceramics, polymers, and certain types of concrete. These materials can be used to achieve the desired level of abrasion resistance while also providing other benefits, such as improved chemical resistance or enhanced aesthetics.
In conclusion, incorporating metallic or non-metallic materials with high abrasion resistance into the floor topping mix can significantly increase the durability and longevity of the floor surface. By selecting the appropriate materials and carefully designing the mix, one can create a floor topping that is highly resistant to abrasive forces and can withstand heavy use over an extended period of time.
3. Surface Hardening Solutions
Concrete flooring can be made more durable and resistant to wear and tear through surface hardening solutions. Among the recommended solutions are sodium silicate, magnesium silico-fluoride, and zinc silico-fluoride. These compounds can also be found in proprietary materials specifically designed for surface hardening.
By applying surface hardening solutions to concrete floors, their resistance to damage and abrasion is increased. Sodium silicate, magnesium silico-fluoride, and zinc silico-fluoride are effective compounds for this purpose. Additionally, proprietary materials that mainly consist of these compounds are available for use in surface hardening.
To improve the durability of concrete flooring, it is recommended to use surface hardening solutions such as sodium silicate, magnesium silico-fluoride, or zinc silico-fluoride. Alternatively, proprietary materials that contain these compounds can also be used. These solutions and materials enhance the wear resistance of concrete floors, making them more resistant to damage over time.
Procedure for Laying of Granolithic Concrete Flooring
The process of laying granolithic concrete flooring involves three main components: the Sand Cushion, Base Concrete, and Topping Layer, as illustrated in Figure 2. The sand cushion and base concrete are installed following the standard laying procedures used in conventional flooring techniques. However, the method for laying the topping layer for granolithic concrete flooring is explained below.
1. Laying of Granolithic Flooring over Base Concrete
The specification requires that the base concrete be laid properly. Once the base concrete is freshly laid, the topping must be placed on it as soon as possible, within 2 to 3 hours depending on the temperature and atmospheric conditions. The base concrete should be still green, but firm enough to support the workers walking over it with planks.
The granolithic mix, with a ratio of 1:1:2, should be deposited on the base concrete in the already laid screed strips, and thoroughly compacted to achieve the desired finished thickness. Any unevenness in the surface of the base concrete should be detected and fixed immediately.
After the topping layer is applied, it should be floated with a wooden float to ensure an even surface. Once the surface has slightly hardened, it should be finished smooth.
For flooring that is laid separately on a hardened base concrete, the surface of the base concrete must be cleaned thoroughly of all dirt, loose particles, and laitance by scrubbing with a coir or steel wire brush. The surface should be wetted with water for several hours, and any excess water should be removed immediately before the topping is applied.
Before laying the granolithic topping, a neat cement slurry must be brushed thoroughly into the prepared surface of the base concrete.
2. Laying of Granolithic Flooring on Suspended Slab
The process for depositing structural concrete involves thorough consolidation in forms, with the surface finished below the desired floor level to allow for the topping layer. If a slope is required for water drainage, it should be given to the concrete while still in its green state. The surface of the concrete should be finished smoothly but with enough roughness to provide a good bond for the topping.
When it comes to granolithic concrete, with a mix of 1:1:2, it should be placed while the structural concrete is still green but has stiffened enough to allow for a mason to tread over it using planks. Once in position, the topping layer should be thoroughly compacted and screeded with a float to achieve an even surface.
For flooring laid over a hardened suspended slab, the base concrete surface should be cleaned with a coir or steel wire brush to remove any scum or laitance before the topping is laid. The surface should also be wetted with water for several hours and any excess should be mopped up before the topping is applied. Finally, a neat cement slurry should be brushed into the surface to prepare it for the topping layer.
| Sl No | Type of topping | Thickness of granolithic concrete floor topping in mm, min | Remarks |
| A | Floor topping laid over base concrete on ground | ||
| i) | Floor topping laid monolithically | 20 | Granolithic concrete floor topping shall be laid monolithic with base concrete. |
| With base concrete | |||
| ii) | Floor topping laid separately on | 40 | Granolithic concrete floor topping shall be laid over separately prepared surface of set and hardened base concrete. |
| B | Floor topping laid over suspended slabs | ||
| iii) | Floor topping laid monolithic | 20 | Granolithic concrete topping shall be laid and finished monolithic with the suspended slab |
| iv) | Floor topping laid over hardened suspended slab | 40 | The granolithic topping shall be laid separately over the specially prepared surface of set and hardened concrete |
| v) | Floor topping laid over cushioning layer | 40 | Cushioning layer of lime concrete of 40 to 50 mm thickness shall be spread over the prepared surface of suspended slab. Topping shall be laid as in Sl.No. (iv) |
Curing and Maintenance
The flooring surface shall be kept moist at least for ten days, and no traffic shall be permitted on the surface during this period.
For proper maintenance of granolithic flooring, frequent washing of the surface with water may be sufficient to keep the floor finish in a clean condition. Any grease stains may be removed using sodium metasilicate, caustic soda, some phosphates, or other proprietary materials.
FAQs on Granolithic Flooring
What is Granolithic concrete flooring?
Granolithic concrete flooring is a type of flooring that is designed for use in heavy engineering factories, workshops, garages, warehouses, and similar environments. The flooring is created using a special type of concrete that is made with carefully chosen aggregate materials. These materials have high hardness, surface texture, and particle shape, which make them well-suited for use in areas that will see a lot of foot traffic and heavy equipment.
To create granolithic concrete flooring, the selected aggregate materials are mixed with the concrete in specific ratios. This creates a dense, hard-wearing surface that is resistant to damage and wear. The flooring is laid in large sections, and the surface is often finished with a trowel or a power float to create a smooth, level finish.
One of the main benefits of granolithic concrete flooring is its durability. This type of flooring is able to withstand heavy loads and frequent foot traffic without showing signs of wear and tear. It is also resistant to water and chemicals, making it a good choice for use in environments where spills and leaks are common. Additionally, granolithic concrete flooring is relatively easy to clean and maintain, which helps to keep it looking good over time.
What are the different methods of laying Granolithic Flooring?
Granolithic concrete flooring can be installed using two distinct methods. The first method is known as monolithic, which involves laying the topping layer within three hours of the base concrete being laid. This method requires the topping layer to be applied immediately to ensure a strong bond between the two layers of concrete.
The second method of laying granolithic concrete flooring is non-monolithic, which involves laying the topping layer after the base concrete has set. This method requires the base concrete to fully cure and set before the topping layer can be applied. This allows for greater flexibility in the construction process, as the topping layer can be applied at a later time once the base concrete is fully cured.
Both methods have their own advantages and disadvantages, and the decision on which method to use will depend on various factors such as project timeline, budget, and specific project requirements. Ultimately, the chosen method must provide a durable and long-lasting flooring solution that meets the needs of the project.
Which are the Surface Hardening Solutions used in Granolithic flooring?
Concrete flooring often requires a surface hardening solution to improve its durability and resistance to wear and tear. There are various compounds that can be used for this purpose, including sodium silicate, magnesium silico-fluoride, and zinc silico-fluoride. Additionally, some proprietary materials are available that primarily consist of one or more of these compounds. These solutions work by penetrating the concrete surface and chemically reacting with the minerals to form a harder and denser layer. As a result, the flooring becomes more resistant to abrasion, impact, and other types of damage. The choice of the surface hardening solution depends on the specific needs of the flooring and the environment in which it will be used.
What is the mix proportion for the topping layer of Granolithic Flooring?
The specified mix proportion for the topping layer of granolithic flooring is 1 part cement, 1 part fine aggregate, and 2 parts coarse aggregate. This mix is essential to ensure the quality and durability of the flooring, as it provides the necessary strength and resistance to wear and tear. Proper mixing and application of the granolithic topping layer are also crucial to achieve a smooth and even surface that is suitable for heavy traffic and high use areas. Therefore, it is important to follow the recommended mix proportion and application guidelines to ensure the optimal performance and longevity of the granolithic flooring.
What is the thickness of topping layer of Granolithic Flooring?
The thickness of the topping layer in granolithic flooring is not uniform and can range from 20mm to 40mm. The variation in thickness is dependent on the type of topping used and the location where it will be applied. It is essential to consider these factors to ensure that the topping layer is of the appropriate thickness for the specific application. This variability in thickness allows for greater flexibility and customization in the construction process, enabling the creation of durable and long-lasting flooring solutions that can withstand various conditions and environments. Therefore, it is important to carefully evaluate the type of topping and its intended application to determine the optimal thickness for the topping layer in granolithic flooring.