PCC Flooring

PCC: This stands for Plain Cement Concrete or Portland concrete in general. This is composed of cement, sand and aggregate but is not used for load bearing structures like RCC. These are like paste to for finishing of flooring and irregularities in walls to make a smooth surface. Plain cement concrete can also be called only “cement concrete (CC)” or “binding concrete”. Materials used for producing PCC: Cement: we generally use Portland cement as bonding material in PCC. Fine Aggregate: Sand is used as fine aggregate.

PRODUCT FEATURES:

❖ heavy duty

❖ fast track installation

❖ attractive finish

❖ maintenance free

❖ Abrasion resistant

❖ Anti Skid and Flexible in nature

❖ Slip resistant

❖ Abrasion resistant

❖ Scratch resistant

❖ Higher temperature resistant

❖ Good leveling properties

❖ Fast & easy application

❖ Economical and Durable

❖ Good chemical resistance

❖ Excellent chemical resistance

❖ Excellent protective properties

❖ Good resistance to abrasion

❖ Non dusting & totally seal the concrete surface preventing dusting

❖ Resistance to thermal shocks

INSTALLATION METHOD:

1. Step 1: Earthwork Excavation For PCC

● Check the bottom level before starting concrete works.

● Keep ready all tools and materials required for PCC work. If required, use shuttering otherwise concrete to be done for full width of excavation.

● Take necessary precautions and safety measures, while removing loose earth, filled earth, and slushy soil in order to avoid sudden collapse of huge earth.

● Safety supervisors must monitor these activities of removing earth, filling in pans, taking out from excavation areas and stacking in safe locations.

● Remove all loose earth from foundation pits before placing the PCC.

● Take care to sprinkle water and ram in the foundation pit before placing plain cement concrete in foundation.

1. Proportioning of Plain Cement Concrete

● The proportioning is done based on the requirement or given specification. Generally 1:2:4 or 1:3:6 mix is used.

● The measurement of material can be done by weight batching or volume batching.

● In volume batching, coarse aggregate and sand shall be measured by measuring a box of 30cmx30cmx38cm of a suitable size equivalent to one bag cement of 1/30 m3or 0.035 m3.

● Sand shall be measured on the basis of its dry volume.

● While measuring the aggregate, sacking, ramming or hammering shall not be done.

1. Mixing of Plain Cement Concrete

Mixing of PCC can be done either manually or by the means of machines :

Hand Mixing

● PCC is allowed to be done by hand-mixing only for small-scale works.

● The base on which the concrete is mixed must be clean, watertight slab or a steel platform.

● Sand and cement are mixed thoroughly followed with the addition of coarse aggregate. Lastly, water is added and the mixture is mixed properly to gain an even colour and consistency.

Machine Mixing

● A measured quantity of dry coarse aggregate, fine aggregate and cement shall be placed in their respective hoppers.

● The dry materials shall be mixed in the mixing drum for at least four turns of the drum after which the correct quantity of water shall be added gradually while the drum is in motion.

● The total quantity of water for the mixing shall be introduced before 25% of the mixing time has elapsed and shall be regulated to achieve the specific water-cement ratio.

● The mixing shall be thorough to have a plastic mix of uniform colour.

1. Laying of Plain Cement Concrete

● The PCC is laid in the layers of not more than 150mm thick and

● thoroughly vibrated by the means of mechanical vibrators till a dense concrete is obtained.

● Wherever needed, hand compaction shall be done with the help of wooden tamping rods so that concrete is thoroughly compacted and completely walked into the corners of the formwork.

● Compaction shall be completed before the initial setting starts that is within thirty minutes of addition of water to the dry mixture.

1. Curing of Plain Cement Concrete

● Freshly laid concrete shall be protected from rain by suitable covering.

● After the concrete has begun to harden- that is about one to two hours after it has been laid- it shall be protected with moist gunny bags, sand or any other materials against quick drying.

● After 24 hours of laying of concrete, the surface shall be cured by flooding with water of about 25mm depth or by covering with weight absorbent materials.

● Curing shall be done for a minimum period of 14 days.

INSTALLATION MATERIALS:

❖ Manual cutter

❖ Drill

❖ Mixers

❖ Rubber boots

❖ Gloves

❖ Compactors

❖ Levels

❖ Tape measure

❖ Moisture Retarders

❖ Vibrators

❖ Trowels

❖ Brooms

❖ Polishers

❖ Concrete moisture meter

❖ Coarse aggregate

❖ Fine Aggregate

❖ Cement

❖ Water