METHOD STATEMENT OF STAMPED CONCRETE | STAMPING FLOORING | Floor Stamping | How to do floor stamping ?
METHOD STATEMENT
1. PURPOSE
The purpose of this Standard Operating Procedure (SOP) is to provide guidance to the installation team as well as the customer about the process of installing UltraTech Décor or similar
2. APPLICABILITY/SCOPE
This SOP is applicable to all the project of Stamped concrete
3. INSTALLATION PROCEDURE
Steps to be followed for Installation of stamped concrete are as follows.
3.1. SURVEY OF THE SITE:
A) Measurements: Take the proper measurements and make any adjustments prior to starting the job.
B) Sub Grade Preparation:
- It should be well drained and should have no free-standing water on the surface.
- It should have required load bearing characteristics.
- The ground beneath the slab needs to be solid.
- Soil should be compacted with machines that eliminate air pockets within the soil.
- In case the concrete is poured on PCC or Existing slabs, it should be cured properly.
- Reinforcements should be used at the Column locations to avoid cracking.
C) Plan out the Band Pattern (if any), how to lay the stamp pattern, Construction Joints, control joints properly. There should not be any confusion for these things after laying the concrete.
4. MATERIAL FOR SITE PREPARATION:
A. There should be enough forming material to complete the job without interception.
B. Arrange for steel channel or wooden formwork. Steel channels should not be bent.
5. CHECK TOOLS AND SUPPLIES
A. Some of the tools which are essential are, Trowels (Magnesium, Wooden and Steel), Edgers, Pounder, Bull Float (Magnesium and Wooden), Pounder, Fresno, Thermocol, Tape measure, Stool (Brick Jointer), Brooms, Textured mats, Rolling Tamper, Sprayers for sealer, acetone, water pump for washing, cutter grinder, brushes for washing the concrete, cloths for cleaning the stamp mats, Bridge for stamping, Level Tube (Bottom Patti / Straight Edge)
B. Some of the materials which are essential are: Colour Hardener, Release agent, Acetone
C. Check the tools and equipment to ensure that they are clean and in good working condition.
D. Replace any tool which is damaged or corroded this time itself.
E. Make sure that you have proper tools and materials to comply with the local standards.
F. Check that you have enough material that you will need to complete the job properly.
6. SAFETY REQUIREMENTs
Following safety requirements should be taken care on site,
A. Safety shoes
B. Helmet
C. Jackets
D. Gum Boots
E. First Aid Box
7. PREPARE SURROUNDINGS:
A. Use plastic with masking tape to cover and protect all surrounding areas of the vicinity where concrete can damage aesthetic of the existing surrounding.
B. Put Thermocol along the wall and along the columns.
8. CONCRETING PROCESS
A. Minimum grade of the concrete should be M 30
B. Minimum thickness of slab should be 3”
C. Slump of the concrete should be max 110 mm
D. Pour the concrete.
E. Concreting should be done exactly as per the level given by the architect. This can be achieved by marking levels prior pouring concrete (DHADA)
F. Level and finish the concrete by using Level Tube (Bottom Patti / Straight Edge) with the screed action. We can also use straight edge vibrator ('Mustang' Concrete Screed) for levelling the concrete.
G. Use rolling tamper to press the gravels in the concrete. This will help in making creamy cement slurry on the top of concreting.
H. Finish the concrete surface by using Magnesium Bull Float. If water cement ratio is high then we can use wooden bull float for bringing the internal water to come on top surface.
I. Finish the edges by using edger.
J. Water should not be added to the concrete once it arrives at the jobsite.
K. Water should not be Sprinkled on the concrete once its finished
L. No single slab should be larger than 15 feet on a side.
M. Fibers should be used compulsorily, and it may be 600 Gms/cum. But it should be added on site.
9. COLOUR HARDENER APPLICATION:
A. After levelling the concrete well next step is to apply colour hardener.
B. Throw the first coat of colour hardener as per standard procedure. In this step 60 to 70% colour hardener is thrown.
C. Finish the first coat colour hardener surface by using magnesium float.
D. Throw the first coat of colour hardener after finishing the first coat.
E. Finish the second coat colour hardener surface by using steel trowel.
F. By looking at the finished second coat, if in some places colour hardener does not look uniform, then at those places throw third coat of colour hardener.
G. It has to be made sure that there is no undulation on the finished surface.
10. STAMPING PROCESS:
A. Timing of the stamping is critical for doing a good job. Concrete should be firm enough to hold the person performing stamping without making a deep impression.
B. Apply release agent for at least three rows of the stamp mats.
C. Release agent application should be optimum.
D. Stamping should be done in a straight line.
E. Make sure that colour hardener is perfectly levelled.
F. Using texture mats all corner areas should be stamped first as at the corners stamping will not be done properly.
G. Place the stamping mats firmly together.
H. Tamp the stamp mats with the pounder lightly as we proceed. Some areas we may not use pounder where concrete is not firm enough.
I. Lift the edge of the stamp pattern to check to see that imprint is complete.
J. In case of some stamps (Ashlar slate, English slate), indicates various configurations such as they are of different colours or marked as A, B, C, D.
K. While removing stamping mats, grab both the handles one time and lift it straight up
L. As stamping process proceeds, use small flexible mats and s tool or chisels to correct any imperfection during stamping.
M. Flexible mats should not be used anywhere except at the corners. This will help in reducing the double joints.
N. A bridge should be made when the width is more. This bridge should be a compulsory tool in the contractor’s tool kit.
O. Clear the double lines caused by stamping. We can use margin trowel, chisel or sometimes reinforcing steel on site to do this
P. Always clean the tools after finishing the work, this will keep the tools in working condition for the next project.
11. CURING:
A. After the concrete finishing is done, the curing process must start.
B. Cover the slab with plastic sheets, this process keeps water in the concrete so that the chemical reaction of hydration can continue. Without this water, the concrete will not reach its design strength.
C. Curing must be done at least thrice a day for normal climate range.
D. For hot weather conditions curing must be done at least 4 to 5 times a day that includes night time too.
12. WASHING:
A. Wash off excess release after 24 hours by using small capacity pump.
B. Release agent should be washed after 5 days to achieve desired effect of stamping colour as specified by the architect. It’s used for double tone effect.
13. CONTROL JOINTS CHECKLIST:
A. For 4 inch thick concrete slab there should be a control maximum of 10 feet in every direction.
B. Control joints must be cut after 36 hours of concreting.
C. Mark the control joint with chalk line or colour available on site.
D. Control joint depths must be a minimum of 1/3 the thickness of the slab and Control joint width must be a minimum of 1/16 inch.
E. Joint thickness near column and intermediate control joints should be minimum 15 mm and 8 mm respectively.
F. No vehicle Movement should be allowed at least for 25 days after stamping to avoid cracks.
14. SEALING:
A. Sealing should be done at least after 27 days after concreting.
B. There should not be any moisture present in the concrete slab.
C. For large areas sealer should be applied by using pump. For smaller areas use roller or 4 inch brush.
D. Apply very thin first coat of sealer. This will help in penetrating the sealer in the concrete slab.
E. Apply second coat of sealer.
F. If the surface is still not shiny enough then apply third coat.
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