Floor Levelling

Concrete Floor Levelling

DC Flooring’s range of levelling systems are fit for both new build and refurbishment projects across a range of industries, including automotive, electronics, food & drink production, pharmaceutical, industrial, airports, healthcare, leisure, and more. Over the years, as industrial and commercial experts, we have provided all kinds of services to businesses across multiple sectors. We offer a whole spectrum of options, as the required product will vary depending on the application – MMA, epoxy, calcium sulphate, polymer, and pump screed, to name a few, which all come with unique advantages.

Why is Concrete Floor Levelling Important?

A smooth and level surface is the foundation to ensure the delivery of a system that will achieve its total life expectancy and performance. Laying new flooring will always be problematic if the incorrect underlayment has been selected or if it has been installed incorrectly.

Best Quality Floor Levelling Services

You may be moving into new business premises, or your existing flooring is inadequate. Regardless of the challenge or requirement, our quality industrial floor levelling services can be tailored to your needs verbatim. Our team is just as capable of giving new life to old and tired-looking floors as they are of preparing new foundations to be used as commercial or industrial facilities.

No matter the design requirements and specifications of your commercial or industrial application, our commitment to quality and compliant floor levelling services is why our services are trusted by companies of all sizes across the UK. All of our concrete and industrial levelling services come with our guarantee for quality workmanship, as well as tailored advice and support at each stage. From prep and application to cleaning, maintenance, and repairs, we offer a turnkey levelling solution to businesses across multiple industries and sectors, regardless of their budget.

Offering a broad range of floor levelling compounds and flooring solutions which meet all compliance, aesthetic, and safety considerations, our quality-driven approach includes:

  • Professional in-house preparation and application
  • ‘Fit for purpose’ and durable flooring options
  • VNA (very narrow aisles) flooring solutions for warehouses
  • Partnerships with the best manufacturers ensure the highest quality materials
  • Dust suppressed scabbling and diamond grinding service included to reduce levels optimally
  • Free initial survey included
  • Applied using the latest, most sustainable technology
  • Very easy to clean and low-maintenance

Why Do we Only Use Quality Screeds for Commercial & Industrial Floor Levelling?

DC Flooring is proud to partner with the screed manufacturing market leaders. This gives us access to the complete range of quality levelling screeds available on the market today.

The range of levelling screeds we use meet BS 8204-7 standards, and offer a number of advantages over other lesser products:

  • Multi-use application depths
  • Quick and easy application – be up and running in 12 hours or less
  • Very flowable and self-smoothing
  • Improved shrinkage profile
  • Very quick drying times
  • Less sensitivity to temperature extremes
  • Can be laid at a relatively reduced thickness in contrast with semi-dry screeds
  • Lower tendency to split or separate on over-watering
  • Can be used with nearly all finishes
  • Superior compressive strength
  • Best-in-class thermal conductivity when used with an underfloor heating solution

We have also chosen manufacturers of the screeds that we use because of their commitment to sustainability which we wholeheartedly share. Owing to their dedication to environmental safety, ethical work practices and sustainability, and are compliant with the ISO 14001:2015 environmental management system certification.

The certification sets the absolute best practice benchmark for several sustainable processes within a floor levelling company, including improved recycling, reduction in carbon footprint, waste minimisation, and packaging reduction, ultimately, improving efficiencies on the limited natural resources we have left on our green planet.

floor leveling

What is VNA flooring?

VNA (very narrow aisle) warehouses require extremely flat and level floors, and we want to make it easy for them to conduct day-to-day operations.

DC Flooring’s team will survey the floor using a profileograph, this shows where the base dips or peaks. Then use either diamond grind level or build up with resin products to get the floor ready for ‘business as usual’.

As your VNA flooring expert, we provide a turnkey solution for ‘very narrow aisle’ warehouses, providing everything from wire guidance, grinding and safety systems to base smoothing and repairs.

Here’s a more detailed look at what our VNA flooring solutions include:

Floor flatness and grinding

The vast majority of warehouses across the UK have not achieved the required standards for VNA “super flat” surfaces. Both old and new warehouses struggle to achieve optimum performance yet do not have a proper VNA system to attain that level of performance. Our expert VNA team will help you achieve the desired level of flatness, using cutting-edge and non-intrusive grinding machinery to make your VNA system super-efficient for forklift truck performance. Our VNA flatness and grinding solutions also ensure that your daily operations can run safely and more smoothly.

Construction joint repairs

Warehouse, industrial and commercial substrates see a fair amount of foot and MHE traffic each day, which means that they will require timely maintenance. Whether you need your VNA floors or free movement area floors to function optimally throughout the year, our floor and joint repair team are only a phone call away. On instruction we can offer a wide range of options to create a flat transition between floor slabs and finishes. Our floor jointing options are easy to use and are ready to receive heavy traffic  overnight

Screeding Techniques and Products we Use

Acrylic Primer

Acrylic primer acts as a bonding agent between the substrate and the floor leveller. It helps to improve adhesion, promote uniformity, and enhance the overall performance of the flooring system.

Before applying, it is essential to properly prepare the subfloor. This typically involves grinding or cleaning the surface to remove dust, dirt, grease, and any previous coatings. Proper preparation creates optimal bonding and long-term durability of the flooring system.

Acrylic primer is typically applied using a brush, roller, or sprayer. The primer should be spread evenly over the prepared floor surface, creating complete coverage.

It has a relatively quick drying time compared to other primers. It typically dries within a few hours, but the specific drying time may vary depending on factors such as temperature, humidity, and application thickness.

The use of acrylic primer offers several benefits for floor screeding and coating applications. It enhances the adhesion of the system to the substrate, reducing the risk of delamination or peeling. Acrylic primers also help to seal porous surfaces, preventing the floor compound from being absorbed into the substrate and meaning a more uniform appearance.

Levelling Compound

Pump screed is an industrial cement-based underlayment levelling compound applied with a pump and pipe for the levelling of floors, prior to the installation of floor finishes. Smoothing compounds are ideal for heavy traffic areas in your warehouse, industrial or commercial facility, where you can resume foot traffic in 2-4 hours and have the floor covering ready after 24 hours.

Our pump applied industrial levelling compounds are a very cost-effective way to have a long-lasting and highly resilient finish in many busy industrial environments – from warehouses and factories to aircraft hangers and more. Using a self-levelling compound can increase the flatness of your floors considerably. Using this method will flat and level subfloors, making it the ideal solution where floor flatness accuracy is essential.

Historically levelling screeds in the UK were made from latex, hand mixed with an electric drill, and hand trowelled. This was very limiting to the size areas that could be installed in a day. These days self levelling compounds are normally water based, meaning that the bagged powder and water are mixed mechanically to produce a flowable mix that can be used to smooth large areas in a relatively short amount of time. They are normally installed with a spiked roller to ensure the floor has consistency throughout and also help prevent air bubbles in the final finish. 

Sand and Cement Screed

If you’re pressed for budget, then our basic low-strength ‘budget option’ will do the job just fine depending on the traffic and finish it is going to receive. Our basic sand and cement may also be adaptable to a number of project demands, offering a reasonably high-performance and durable leveller tailored to your exact needs. Largely used as an infill screed and flooring underlay, our sand and cement screen offers good flexural strength, reduces shrinkage & cracking, and minimises permeability – a very cost-effective solution all in all, particularly if you’re on a tight budget.

Epoxy Primer

Epoxy primers are specifically designed to bond with high-strength flooring systems. They provide excellent adhesion, enhance durability, and help to prevent moisture vapour transmission from the substrate. Epoxy primers are commonly used in industrial, commercial, and residential flooring projects.

Epoxy Mortar

Epoxy Repair Mortar is our most versatile levelling product. It boasts extremely high strength; the formable texture and fast curing properties make it an excellent product for floor repairs and dealing with ‘problem areas’. Epoxy mortar has been used across multiple industries and commercial projects for years. In fact, by addressing issues in your floor early on, you can add decades to its life, especially when you add a professional finish. Our epoxy mortar solution and finishes are highly suitable for heavy traffic areas, providing a high-performance solution for cracked, damaged, and decaying concrete, either internally or externally. 

Polymer screed

Polymer screeds have a synthetic polymer resin compound which gives them increased toughness and bonding capabilities. As a result, permeability is reduced, while flexural strength is also increased, all the while minimising shrinkage and cracking. It is an excellent high-performance screed that works well at thinner sections and truly proves its worth where normal thickness is either not practical or cannot be achieved. DC Flooring’s polymer screed is perfect for floor slabs and other flooring applications as well. In fact, its properties also make it highly suitable for all kinds of floor refurbishment and repair work.

Polymer screeds are always useful where a high degree of flexibility is required – i.e. a need to improve flexural fatigue resistance and overall flexural strength – and where you require improved performance – e.g. better abrasion and impact resistance against daily site traffic.

MMA Screed

If you require a hard-wearing and impervious finish and do not have the luxury of time, then our MMA screeds will easily live up to your project demands. Our MMA has been used across multiple industries and commercial applications, including food and drink production facilities, hospitals and healthcare facilities, laboratories, pharmaceutical plants, commercial kitchens, multi-storey car parks, and more.

The chemical-resistant, extremely high strength and hygienic floor finish is also very easy to clean and offers super-fast curing characteristics – our MMA mix can cure in as little as 1 hour, getting you back in business in practically no time!

The Types of Self-Levelling Compound

There is a large choice of different self-levelling compounds available with different characteristics. Flexible renovation systems that can be installed over wooden and timber substrates, rapid drying levellers for quick turnaround jobs, moisture-resistant products for damp areas, and products that can even adhere to metal. Lightweight options for large skyscraper projects, pre-coloured finishes designed as actual wearing surfaces, and compounds that are designed to go over existing tiled areas are also options that you can select for your project. 

Why Should You Hire DC Flooring?

Although this vast amount of choice may seem daunting, help is at hand. At DC Flooring we regard subfloor preparation and underlayment selection as even more important that the finishing product that you choose. What is the point of installing a beautifully finished resin or alternative floor finish, only for it to delaminate, degrade or fail long before it was designed to? Your project is only as good as the base that it is applied to.

One of the main reasons our clients choose to work with us on their projects is the fact that we can prepare, install a levelling system and then supply and install any floor finish of their choice. This gives us unique insight and experience in selecting the right system for you and your specific needs.

We are very strict in the products and processes that we use. We will always advise customers of the benefits of doing the job properly, and the dangers of not carrying out the tried and tested practices. Other companies may be happy to cut corners or install systems without the required subfloor prep to lower the price of the installation to win the job. For us this is a false economy, as there is a huge difference between price and value. We have in the past been asked by customers to not undertake the correct preparation, as professionals this is something we cannot do.

If this is the situation then unfortunately we might not be the right company for you. We would rather do the installation correctly or not at all, as our ethos is building long term relationships, which isn’t going to happen if your floor fails.

All subfloor preparation is done in-house using our specialised equipment – shotblasting, scabbling, and concrete grinding.
You’re only a phone call away from investing in leading-class flooring systems, all approved by FeRFA.

FAQs

How do you level an uneven floor UK?

Before attempting to level the floor, it’s important to determine the cause of the unevenness. It could be due to structural issues, settling of the building, or other factors. Understanding the cause will help you decide on the appropriate solution.

If the unevenness is significant or if you’re unsure about the cause, it’s advisable to consult with a structural engineer or a professional contractor. They can assess the situation and provide expert advice on the best course of action.

If the unevenness is minor, you may be able to use a self-levelling compound. This is a liquid mixture that can be poured over the uneven floor to create a flat, level surface. Follow the manufacturer’s instructions for mixing and applying the compound. Typically, you’ll need to clean the floor thoroughly, apply a primer if required, mix the compound according to instructions, and pour it onto the floor. Use a trowel or a levelling tool to spread the compound evenly and allow it to dry as per the manufacturer’s guidelines.

In cases where the unevenness is more significant, you may need to consider installing a new subfloor. This involves adding a screed or other suitable material over the existing floor to create a level surface. Make sure to secure the subfloor properly to ensure stability and prevent delamination.

Professional solutions: For more complex situations, such as structural issues or major floor levelling, it’s best to consult with a professional contractor or a structural engineer. They can assess the problem accurately and suggest appropriate solutions, which may involve more extensive renovations or repairs.

Remember, it’s important to prioritise safety and consult with professionals if you’re uncertain about the process or the cause of the unevenness.

How much does it cost to level a floor UK?

The cost of levelling a floor in the UK can vary widely depending on several factors, including the extent of the unevenness, the size of the area, the type of flooring, and the specific method used for levelling. Additionally, labour costs and regional variations can also affect the overall price.

To give you a rough estimate, here are some general price ranges for floor levelling in the UK:

  1. Self-levelling compound: If the unevenness is minor and you opt for self-levelling compound, the cost can range from £5 to £15 per square meter for the compound itself. Keep in mind that this does not include the cost of tools, primers, or any additional materials you may need.
  2. Professional floor levelling: If you hire a professional contractor to level the floor, the cost can vary significantly depending on the complexity of the job and the specific requirements. As a rough estimate, you can expect to pay anywhere from £20 to £50 per square meter for professional floor levelling services. This price typically includes the cost of labour, materials, and any additional preparatory work that may be required.

It’s important to note that these figures are approximate and can vary based on individual circumstances.

If you are trying to undertake a diy project, there are many how-to guides and products are available to order online or to collect at local building depots.

Additionally, if there are underlying structural issues or extensive repairs needed, the cost may increase significantly, and it’s advisable to consult with a professional for an accurate assessment and pricing.

Is concrete levelling worth it?

Concrete levelling is a worthwhile solution for addressing minor to moderate unevenness in floors, providing cost-effectiveness, convenience, and compatibility with different flooring types. However, for more severe structural issues or extensive floor problems, other options may be more suitable. Consulting with professionals will help you make an informed decision based on the specific circumstances of your project.

How thick should floor levelling be?

The thickness of floor levelling can vary depending on the specific requirements and the extent of the unevenness you are trying to correct. In general, floor levelling compounds are typically applied in thin layers, ranging from a feather-edge (as thin as 1-2 mm) up to any thickness.

Here are some general guidelines for floor levelling thickness:

  1. Minor unevenness: If you’re dealing with minor surface imperfections, such as shallow low spots or small depressions, a thin layer of floor levelling compound ranging from 1-2 mm (feather-edge) to 5 mm coverage may be sufficient.
  2. Moderate unevenness: For slightly more significant unevenness, such as low areas or small slopes, you can apply a thicker layer of levelling compound ranging from 5 mm to 12 mm.
  3. Major unevenness: In cases where there are more significant level differences or deeper depressions, there are different options that are available depending on the strength required, curing time required etc.

Keep in mind that these guidelines are approximate and can vary depending on the specific product and manufacturer recommendations. 

Additionally, if you are unsure about the thickness or have a complex levelling situation, it’s advisable to consult with a professional contractor or a structural engineer who can assess your specific needs and provide appropriate recommendations.

What is the difference between floor leveller and concrete?

Floor leveller and concrete are both used to create level surfaces, but they differ in terms of their composition, purpose, and application. 

Levellers are typically a self-levelling compound made from a mixture of cement, aggregates, polymers, and other additives. It is designed to have a flowable consistency, allowing it to level itself out when poured. On the other hand, concrete is a mixture of cement, aggregates (such as sand and gravel), water, and sometimes additional additives. 

Floor leveller is specifically formulated to correct minor to moderate surface imperfections and create a lump free and level substrate. It is a handy product primarily used to provide a level base for the installation of resin, tiles, vinyl, laminate, or other coverings. Concrete, on the other hand, is a versatile construction material used for a wide range of applications, including foundations, walls, pavements, and structural elements.

One of the key features of floor leveller is its self-levelling nature. Once poured, it flows and spreads out to create a level surface, eliminating minor irregularities. Concrete, however, requires more manual work and trowelling to achieve a level finish. It needs to be placed, compacted, and floated to create a level and finished surface.

leveller is typically applied as a thin layer, ranging from a feather-edge (1-2 mm) up to a maximum thickness of around 25 mm per application. It is poured onto the and spread using a trowel or a levelling tool. Concrete, on the other hand, is commonly used in thicker applications for structural purposes and can be poured and formed into various shapes and sizes. 

Concrete is also known for its high compressive strength and durability, making it suitable for load-bearing structures. It can withstand heavy loads and endure outdoor conditions. Floor leveller, while providing a level surface, is not designed for structural purposes.

In summary, floor leveller is a self-levelling compound used to create a smooth level surface for flooring installations, while concrete is a construction material with broader applications and structural capabilities. Each has its specific purpose, composition, and application method, tailored to different needs in construction and building projects.

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