I have project, rather an opportunity to help a friend out who is opening up a store in Galveston, TX. Money is limited as they have been screwed by all their insurance companies.
Anyways, I was able to locate some inexpensive snap and click laminate flooring to cover the 3000 sf retail space. The existing floor is concrete in not so good shape. Normally I would float the floor with Custom Self Leveling compound. Can’t do it here-way too much money.
I have never used gypcrete , but I was thinking that maybe we could use some hot mud, like USG 45 setting compound to flatten out the surface. I know it is not the best way to do it, just trying to help out a friend in need.
Your thoughts?
Thanks Bruce
Edited 7/17/2009 9:11 am by Hiker
Edited 7/17/2009 9:12 am by Hiker
Edited 7/17/2009 9:12 am by Hiker
Edited 7/17/2009 9:13 am by Hiker
Replies
Hot mud would probably work, after all, people used to use FixAll for the same purpose. I would be concerned with the effects of moisture though.
I would guess that Galveston has a lot of ground water, being about 6" or so above sea level, so I'd test the concrete for wicking moisture. Tape 12" x 12" pieces of 2 mil clear plastic in several parts of the floor, both across cracks and where there are no cracks and see after a day or two if there is moisture collecting under the plastic.
The floor is six feet above grade so the only water it will see is when the next hurricane hits and if it is like Ike, the water level was about 9' above grade.
It is a laminate so it will probably disintegrate as quickly as the hot mud would.
Look at Weldbond white glue. if you read the instructions you can make your own self leveling Cement. I use a wee bit in all hand mixed crete and it makes it much stronger. ask my plumber who was muttering about how hard it was.
I've had decent luck doing large areas on the cheap with thinset mortar. It shrinks some but not too badly. Cheaper than hot mud, way cheaper than floor leveler. Use some thinned white glue as a bonding agent.
Just don't say you heard it here!
Thanks to all for the input. I like the idea of the thinset.
What consistency do you mix it? Normal moisture or wetter or drier. It would seem wetter would make is slightly easier to slick up
ThanksBruce
A little wetter than normal, but not super wet or it will shrink and crack too much. You might want to set up screed boards.
We installed a replacement gypsum roof deck about 8-9 months ago. Original lasted about 30 years. It is surprisingly stong and duraqble as long as it stays dry. You might check with a commercial roofewr for sources of supply.
"Put your creed in your deed." Emerson
"When asked if you can do something, tell'em "Why certainly I can", then get busy and find a way to do it." T. Roosevelt
Would a concrete grinder on the high spots make it flat enough, or at least make the leveling easier and use less material?
You may want to get a cheap concrete grinder crew in there before you begin the leveling process. I bet the labor is cheap there, unless it suffers from post-hurricane inflation.
Billy
Would it be possible to polish the concrete like they do at Lowes? Even with some bad spots it's a nice looking floor.