11 Self Leveling Material Manufacturers in 2024

Explore the world of self leveling materials, their applications, and foundational principles. Below is an updated list of eleven prominent self leveling material manufacturers along with their rankings for the year 2024. Leading the pack are 1. LYONS MANUFACTURING, INC., 2. ARDEX Americas, and 3. CTS Cement Manufacturing Corporation.

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Understanding Self-Leveling Material

Self-leveling materials primarily consist of gypsum or cement-based compounds known for their natural flow properties.

These innovative materials have the unique ability to create a level and uniform surface simply by being poured, earning them the nickname 'leveler.' When comparing them to traditional mortar, which serves a similar purpose, self-leveling materials stand out for their ease of application. Unlike mortar, which greatly relies on the skill of the installer, self-leveling compounds can be poured directly and smoothed with a consistent finish achieved via a tonneau.

Applications of Self-Leveling Materials

These materials are essential for preparing smooth subfloors in various settings.

Common applications include installations in buildings, multi-family residences, educational institutions, medical facilities, heavy-duty industrial floors, covered parking areas, food processing areas, and waterproofing in above-ground or basement settings. Self-leveling materials also play a crucial role in preparing subfloors to facilitate the installation of tile and other flooring types.

While self-leveling materials generally incur a higher material cost when compared to mortar, their quick installation process often results in a more economical overall project cost.

However, achieving a significant thickness with a single application can be challenging, necessitating subsequent layers for depth beyond 20 mm, where traditional mortar is preferable.

Mechanics Behind Self-Leveling Materials

The functioning of self-leveling materials involves the pouring of a slurry composed of gypsum and mortar onto the floor, which flows naturally to create a smooth surface.

The self-leveling process unfolds through several key stages:

1. Pre-Construction Assessment

Initial preparation involves leveling the area and setting reference lines that outline the horizontal and central positions, including the centerlines of columns as well as the finished surface of walls. To prevent leaking of the material, gaps are sealed with mortar while shielding from direct sunlight and wind.

2. Substrate Preparation

The substrate then requires thorough cleaning using a specialized brush. Any oil and protruding surfaces are smoothed to enhance bonding between the floor and the self-leveling material.

3. Primer Application

A primer is applied to the surface and allowed to dry, establishing a solid foundation for material adhesion. This base coat is critical for improving the grip of materials that may not bond appropriately to paint.

4. Pouring Self-Leveling Material

Once preliminary preparations are complete, the self-leveling material is ready to be poured. It’s crucial to ensure the material is evenly distributed; any ripples or air bubbles need to be smoothed out with a trowel for a flawless finish.

5. Curing and Drying

Following the pouring, the curing process begins. It's vital to prevent rapid drying during this period by keeping windows closed and minimizing airflow to avoid surface irregularities. After confirming sufficient curing has taken place, windows can be reopened to enhance ventilation and aid in drying.

6. Final Inspection and Corrections

Finally, a thorough inspection is conducted after the material has set. This inspection checks the overall level of the floor and identifies any imperfections such as joints or discrepancies in height that necessitate corrections.

Categories of Self-Leveling Materials

Self-leveling materials can be split into two primary categories: gypsum-based and cement-based.

1. Gypsum-Based Self-Leveling Materials

These materials are stable during curing and are characterized by their resistance to cracking and dimensional changes, thanks to their hydration processes.

2. Cement-Based Self-Leveling Materials

These formulations often boast high strength and may be suitable for exterior applications. Once cured, they are also notably resistant to water.

Self-leveling concrete comprises polymer-modified cement that exhibits excellent flow characteristics and, unlike conventional concrete, does not require excessive water for placement. This type of concrete is ideal for achieving flat, smooth surfaces with compressive strength equal to or greater than that of traditional concrete, especially before the installation of flooring materials. As flooring products demand greater flatness and smoothness, self-leveling concrete has gained immense popularity in various applications including thicker vinyl and larger ceramic tiles.

In contrast, self-consolidating (or self-compacting) concrete (SCC) is a distinct mixture characterized by its highly fluid consistency, derived from superplasticizers, allowing it to flow and level itself effectively.

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Historical Context

Self-leveling concrete was first developed by Axel Karlsson of Sweden, who created the product by combining wood glue, fine sand, and cement with specific additives. The term for this product, flytspackel, translates directly to "floating putty."

The label self-leveling emerged from a patent filed by the company Lafarge in subsequent years, designed to set it apart from traditional concrete, which is typically stiffer and requires considerably more labor for optimal placement and finishing.

Applications

Self-leveling concrete is categorized mainly into two classes: underlayments and toppings. Underlayments are used over existing subfloors to rectify surface irregularities before installing floor coverings such as vinyl, tile, wood, or carpet. Conversely, toppings serve as the final floor layer, eliminating the need for additional covering. Common applications for concrete toppings can be found in warehouses, light industrial contexts, retail spaces, and institutional facilities. These toppings can furthermore be enhanced with color, stains, cuts, or mechanical polishing to yield an appealing decorative finish.

When poured, self-leveling concrete takes on a viscosity reminiscent of pancake batter. Tools like gauge rakes assist in moving the material without over-thinning, and light tooling helps break the surface tension, ensuring even consistency throughout. The standard application thickness for these products ranges from 1/4 inch (6 mm) to allow sufficient mass for flow, while some modern formulations can be installed with thicknesses as low as 1/8 inch (3 mm).

Related Concepts

• Self-consolidating concrete (also known as self-compacting concrete, abbreviated as SCC)

Further Reading

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