A. Substrate preparation:
A1. Absorbent substrates
The application should take place on properly cured substrate without shrinkage and with a moisture content up to 4%. Waiting time depends on the type of application.
Remove all loose elements of concrete or cement based mortars, until a solid and mineral substrate with a tensile strength larger than 1,5 N/mm² is obtained. The substrate should be clean of dust, dirt, oil, grease, and any other elements that might affect the bonding between the substrate and the decorative layer.
Existing cracks on the substrate, should be repaired with the two-component epoxy resin adhesive EPO FLUID in a way that ensures the monolithic function of the substrate.
In case of substrates previously coated, any remaining residues should be completely removed by mechanical means till we obtain a solid and mineral substrate.
In cases where concrete reinforcing bars have been exposed, it is recommended to remove the loose rust mechanically or apply RUST CONVERTER. This is followed by application of NOVAFER on the reinforcing bars and final step of this restoration process with one of the concrete repair mortars RC 340 or RC 440 depending on the type of application.
Substrates with inadequate mechanical strength are not suitable for the application of terrazzo coverings. In these cases, the substrate must be removed and then levelled to the appropriate thickness with a suitable mortar.
For floor applications that require a fast substrate levelling process, with a thickness of 10 to 80 mm or even greater, it is recommended to use NOVACEM RAPID.
If substrate levelling of vertical or horizontal surface is required, in a thickness of 2 – 40 mm, use RC 220 or RC 240 depending on the type of application.
A2. Non-Absorbent substrates:
It is recommended to apply terrazzo coverings to absorbent and solid substrates. The application on substrates of zero absorbency such as metal, existing coverings of ceramic tiles, floor paints, etc. should be avoided, although it is possible under certain conditions and only if the stability of the construction, the adhesion and the compatibility between successive layers can be ensured. In such cases of doubt, it is recommended to precede a test application.
To apply a terrazzo covering on a non-absorbent substrate, the following should be reviewed:
- Existing coverings such as terrazzo, ceramic tiles and marble, should be well bonded to the substrate
- The substrate should be clean of dust, dirt, oil, grease and any other elements that might affect bonding between the substrate and the decorative layer
- Substrates with elasticity or special constructions that might be susceptible to oscillation movements or strong vibrations should be inspected if they are suitable to receive terrazzo coverings
- Subject to the type of dirt and substrate it is recommended to mechanically remove or chemically clean with one of the following products:
B1. Application on absorbent substrates:
Prior to the application, wet the substrate with water and remove the excess by using air or sponge.
On indoor, absorbent and solid substrates and on areas without increased humidity, the use of a bonding slurry consisted of 1 part water / 1 part SBR 50 and 3 parts NOVACEM TERRAZZO is recommended.
The terrazzo mixture is then applied ‘wet on wet’ on the slurry.
Outdoors or in areas of increased humidity such as:
- bathrooms, countertops
- exterior floors, terraces, pedestrian areas, public squares, sidewalks
it is required to waterproof the surface by using compatible cementitious based waterproofing compounds such as SC ELASTIC EASY or SC 200 PENETRATE. The application of the waterproofing layer is performed in a minimum total thickness of 2 mm, with the incorporation of the fiberglass mesh NOVAMIX FIBERGLASS NET as a guide for the final thickness of the waterproofing layer.
In any case of doubt, compatibility test should be performed between the chosen cementitious waterproofing compound and the existing absorbent substrate.
The terrazzo mortar is bonded to the substrate by using a slurry consisted of 1 part water / 1 part SBR 50 and 3 parts NOVACEM TERRAZZO. The terrazzo mixture is applied ‘wet on wet’ on the slurry.
B2. Application on non-absorbent substrates:
On reduced absorbency surfaces such as existing terrazzo, well-fixed ceramic tiles or marble the terrazzo mortar is bonded to the substrate by using NOVAMIX EPO FLUID. The terrazzo mixture is applied ‘wet on wet’ on NOVAMIX EPO FLUID.
If the substrate is solid and non-absorbent a compatibility test between the substrate and the terrazzo covering should be performed and the suitability of the application in general must be checked beforehand.
Deformable substrates such as metal surfaces, wood, linoleum, or incompatible substrates such as epoxy, polyurethane coatings or paints etc. are considered unsuitable to receive terrazzo coverings using NOVACEM TERRAZZO.
In such cases where the substate is not suitable to receive terrazzo coverings, the existing coverings/coatings should be demolished and reconstructed by using suitable levelling mortar depending on the type of application (see A1 above). Otherwise, in the short or long term the incompatibility might result in delamination of the terrazzo covering.
B3. ‘Wet on wet’ application on new concrete slabs with minimum total thickness 60 mm:
In cases where the final thickness of terrazzo covering including the substrate is designed to be minimum 60 mm, a ‘wet on wet’ application of the mix can be done on concrete C20/25.
The application of NOVACEM TERRAZZO mix of minimum thickness 10 mm is performed over a minimum 50 mm thickness fresh concrete (type C20/25) layer, as soon as it becomes walkable.
By following this technique, an almost monolithic bonding of the mix with the substrate can be ensured. Caution: If the concrete layer becomes dry, this technique cannot be applied.
C. Preparation of the mix:
According to the ratios shown at the TDS of NOVACEM TERRAZZO, add the quantity of water required in a suitable container or an appropriate portable concrete mixer.
While stirring slowly, add NOVACEM TERRAZZO to the container and then the chosen PLANOCOLOR GRANULATES.
In case the design mix requires the use of a suitable color pigment such as NOVACOLOR UNIVERSAL, NOVACOLOR OXIDE, NOVACOLOR CARBON, mix the pigment with the water prior to the addition of NOVACEM TERRAZZO and PLANOCOLOR GRANULATES. To ensure stability of the final color, the container of the color pigment should be rinsed with the amount of water used in the mix and be clean (proof that 100% of the pigment is used).
Mix for at least 3 minutes until a homogeneous mortar free of lumps is obtained.
D. Consumption of the mix:
The consumption depends on the type of application (covering thickness and mix composition). An average dry mix consumption ranges between 20 +/- 1 kg/m2 per cm of covering thickness.
E. Application of the mix and surface treatment:
The mix is applied by means of a flat spatula, trowel, or suitable spraying systems, depending on the final composition of the mixture and the type of application, by applying adequate pressure on the fresh mortar surface, in order to compress the material and remove air bubbles that might have been ‘trapped’ in the mix during the stirring process.
Then, level the surface by using an appropriate metal spatula or suitable levelling tool.
If during the levelling process, bumps due to air trapped inside the mortar during mixing process occur, then by means of appropriate stick or trowel, ‘break’ them to allow trapped air to ‘escape’. Leveling of the layer should take place while the mortar is still fresh.
The application thickness usually depends on the maximum grain dimension of the granulates used, where the minimum layer thickness is 2 – 3 times the maximum grain size of the granulates. In any case, the recommended minimum thickness of terrazzo coverings on floors is 15 – 20 mm.
The mortar must be applied under normal conditions within 1 hour after mixing. After this period do not try to ‘soften’ the mix by adding water.
Low temperatures extend the open time of the mix while high temperatures drastically reduce it. The temperature of the mixing water, as well as the surface temperature of the substrate might also affect the workability.
It is recommended to avoid long sunlight exposure of the materials before use, otherwise the working time is reduced drastically.
Important: In general, the terrazzo coverings created with the use of hydraulic binders NOVACEM TERRAZZO, encounter the same limitations of application of concrete and cement based mortars.
E1. Creation and protection of the surface with terrazzo finish:
The final treatment and protection process of the final terrazzo surface depends on the conditions and requirements of each application. For example:
- the required gloss level, e.g. exterior areas with a requirement for a ‘honed’ non-slip final surface
- the grinding system applied (wet grinding, dry grinding or combination with chemical treatment such as crystallization)
- special requirements such as avoiding the use of solvent based products
- composition of the mixture
The grinding process must be done by a qualified professional with appropriate equipment.
A typical mechanical grinding process is as follows:
- Depending on the desired grinding level, metal or resin grinding discs are used with an indicative sequence: number 24/50/100/150/200/320/400/800/1500/3000 and so on
- To facilitate the grinding process, it is recommended to use the mineral hardener PLANOFINISH CH
- The filling of micro-holes resulting during the grinding process can be done by using NOVACEM MF mortar or exclusively for interior by using the epoxy paste PLANOFINISH CRYSTAL
- Depending on the desired polishing level, it is recommended to apply the following waterproofing compounds when the moisture content of the terrazzo is less than 4%:
- For surfaces of low polishing level, the use of PROTECT 300 S is recommended
- For terrazzo of high polishing level and reduced absorbency, it is recommended to use the waterproofing agent PROTECT 900 S
- In cases where there is a requirement to further ‘highlight’ the granulates or the shade of the bonding mortar, PROTECT 400 WET can be used
- If a high polishing level and protection is required, it is recommended to apply the surface protection PLANOFINISH HP, only indoors and without stagnant water, by using a suitable high-speed rotary brush (1500 – 2000 and above), either after waterproofing or after finishing the mechanical grinding process
- In cases where there is a requirement to further increase the gloss of the final terrazzo surface, PLANOFINISH BRILLANTE can be used, which also provides a high level of protection against dirt
E2. Treatment and surface protection by using solvent-free products:
For cases where there is a requirement for surface treatment using only solvent-free products:
- The filling of micro-holes resulting during the mechanical grinding process is done exclusively by using the NOVACEM MF mortar
- Waterproofing can be done by using the water based waterproofer PROTECT 200. The application of PROTECT 200 must be done on a mechanically grinded surface up to No 400. Otherwise, there is a risk that the waterproofer will not be able to penetrate, thus creating a surface film
- In cases where there is a requirement to further ‘highlight’ the granulates or the shade of the bonding mortar, PROTECT 400 WET can be used
- After the completion of the mechanical grinding process or the application of waterproofer PROTECT 200, apply the surface treatment PLANOFINISH HP, by using a high-speed rotary machine (1500 – 2000 and above), achieving a high polishing and protection level of the final surface. PLANOFINISH HP surface protection is recommended to be applied only indoors, without stagnant water.
- In cases where there is a requirement to further increase the gloss of the final terrazzo surface, PLANOFINISH BRILLANTE can be used, which also provides a high level of protection against dirt
In any case, the application of any chosen waterproofing agent is performed, only when the humidity of the terrazzo covering is less than 4%. This applies to all waterproofers listed here, even those that are water-based.
F. Expansion joints / control joints:
In any case, existing expansion joints or control joints on the substrate must be followed by the final surface covering. The location of each expansion/control joint depends on the use of the surface, the geometry and the location.
Control joints must be provided on each surface change (wall-to-floor joints) and every 4 – 5 running meters in length, with a maximum ratio between long and short side 2:1.
These joints are filled with prefabricated joint profiles of suitable cross-section and composition, depending on the design intent requirements.
G. Maintenance of terrazzo surface:
The terrazzo coverings are surfaces that mainly contain granulates that often have different physical and chemical properties that affect the absorbency or strength to resist chemical and mechanical stresses.
The chosen surface finish from polished terrazzo to ‘honed’ terrazzo surface, significantly affects daily and special maintenance which is why the type of application and the specific use should be carefully considered at the design stage.
Indicative recommendations for daily and special maintenance for terrazzo coverings can be found below. In case of doubt, it is recommended to have a cleaning test in a non-visible area.
- For day-to-day cleaning process it is recommended to use the neutral detergent NEUTROCLEANER which normally does not affect the surfaces
- Oily stains, rubber wheel marks, residues of smoke in walls can be cleaned by using the alkaline based detergent ALCALINE CLEANER
- Coffee, colored non-oily household stains are cleaned by using MARBLE NO SPOT
- Varnishes, synthetic stains, paints are cleaned by using PAINT REMOVER or PAINT REMOVER GEL
- Cementitious residues, rust and other inorganic hard pollutants are cleaned with an acidic detergent such as ACID CLEAN, diluted in water, subject to the requirement and with a spot application. Always keep in mind that acidic detergents may damage the polishing. In case of doubt, it is recommended to have a cleaning test in a non-visible area.
Recommendations:
- Apply over a structurally stable and well-prepared substrate.
- The application substrate must be solid, level and compatible with the terrazzo covering. In cases where levelling of the substrate is required, use a suitable levelling material (see A above)
- Existing coverings must be compatible with the terrazzo mortar and well-anchored to the substrate. Deformable substrates such as metal surfaces, wood, linoleum, or incompatible coatings such as epoxy, polyurethane paints etc. are considered unsuitable to receive coverings using NOVACEM TERRAZZO
- Always use the compatible waterproofing compounds SC 200 PENETRATE, SC ELASTIC EASY which have been tested and are suitable for such applications
- Avoid application during direct exposure to sunlight and/or strong wind as well as rain, in external or exposed areas
- Do not apply when temperature of the substrate and environment is lower than +5°C or higher than +35°C
- On hot days use cool water and moisten the substrate with cold water or ice cubes. Avoid exposing the materials to high temperatures before use
- Use potable water for mixing
- Do not add water or additives once the mix starts to set. If necessary, keep stirring the mixture until the time of application
- Do not overlap existing expansion or control joints of the substrate
- Do not apply upon uncured substrates or substrates with continuous rising humidity or in wet areas, without first waterproofing and eliminating the source of humidity
- Permanent water immersion after 7 – 10 days. In this case, the use of varnish or other protective coating is not recommended, with the exception of the hardener/densifier PLANOFINISH CH PLUS
- In cases of doubt due to the particularity of the composition of the mixture, before the application of varnish or waterproofing protection, a test area must be applied
- Do not add cement, gypsum, lime or other materials that may affect the properties of the mortar
- It is recommended to mix with granulates of appropriate granulometry such as PLANOCOLOR GRANULATES, in order to ensure a mixture composition with minimal shrinkage and higher strength
- Do not apply upon deformable substrates or substrates subjected to vibration
- The use of NOVACEM TERRAZZO or PLANOCOLOR GRANULATES from different batches is not recommended
- Colored marble granulates may increase their gloss in the long run, if cleaned with strong chemicals
- In case where specific color is required, it is recommended to mix with NOVACOLOR CARBON, NOVACOLOR OXIDE, NOVACOLOR DESIGN or NOVACOLOR UNIVERSAL in appropriate proportions. Keep in mind that pigments can discolor due to contact with strong cleaners e.g. in floors or swimming pools
- Application must be done by professional applicator
- All the usual precautions taken when applying concrete, such as curing in a wet environment, should also be applied when creating terrazzo coverings by using NOVACEM TERRAZZO
- Refer to the Technical Data Sheets as well as the Safety Sata Sheets of the products listed here
Cleaning:
Tools used during the preparation and application can be cleaned with water while NOVACEM TERRAZZO mixture is still fresh. If hardening occurs, cleaning can be done only by mechanical means.
Legal Notice:
The technical data and recommendations included or listed are the outcome of laboratory measurements combined with our current knowledge and expertise. All information and specifications should in any case be considered as indicative. The Company makes every effort to ensure the accuracy of the information provided herein. Product specifications are subject to change without notice and may differ from product images. Due to printing and application procedures, the colors displayed here should be considered as indicative. In particular, variations in materials, substrates and on-site application conditions are such that no warranty can be given or implied reference to the suitability of the materials for trading or use for a particular purpose and conditions of any given project. Anyone interested in using the product must ensure beforehand that the product is suitable for the intended use and in any case, the user is solely responsible for any outcomes associated with the use of product. Among other things, the Company is not responsible for any normal wear or tear from environmental or any other unsuitable conditions. We reserve the right to revise or change the data herein without prior notice. Restrictions and disclaimers apply to the extent permitted by applicable law. The Company has a Technical Support Department, which has exclusive responsibility for providing technical advice and solutions, addressing relevant issues. Requests to the Technical Support Department are addressed and answered, only in writing. For the latest and valid version of the Technical Data Sheet, the user of the material must refer to our website www.novamix.gr.
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No part of the above may be reproduced, stored in a retrieval system or transmitted by any means, electronic, mechanical, photocopying or otherwise, without prior permission of DOMOCHEMICAL SA. The technical data and recommendations contained here correspond to the best of our knowledge and experience. All the above mentioned information in any case should be considered as merely indicate and subject to confirmation after long term practical applications. For this reason anyone interested in using the product must be sure beforehand that the product is suitable for the envisaged application. In every case the user alone is fully responsible for any consequences deriving from the use of the product. We retain the right of renewal of the data shown here, without warning.
