Contec Ferroplan® - CONTEC ApS

INSTALLATION MANUAL
Contec Ferroplan ®
INDUSTRIAL FLOORING
GENERAL
The Contec Ferroplan is an unique system that
can be placed on sub bases which are weak,
cracked or polluted and are thus difficult or not to
prepare for a normal Contop topping. The Contec
Ferroplan System can also be applied on for instance
tiles, coatings, epoxy, asphalt, steel, etc.
The Contec Ferroplan System can be placed both
as a “bonded” topping or overlay or as a “nonbonded”
topping or overlay. The Contec Ferroplan
System can be used for structural rehabilitation
and strengthening from constructions. The requirements
for the sub base are not as strict as
with the other Contop toppings. It is important that
all the loose parts, dust and debris are removed.
We recommend to prepare the surface from the
base by shot blasting or cold milling to get a clean
structure at the surface. The Contec Ferroplan
System can be placed without joints en sometimes
even crack bridging is possible; this is however
depending on the existence and the type of
joints and the reason for the cracks in the sub
base. In case that there is chemical- or other pollution
in de sub base which can influence the setting
of the mortar negative, than it will be necessary
to cover the sub base with plastic foil, asphalt
emulsion or with an epoxy coating which is sprinkled
off with fine aggregates. Usually cement
based toppings are placed in lanes with a width of
4 – 5 m and placing, compacting, finishing and
curing must be done one upon another. For this it
is necessary that the application is well prepared
before and that the floor layers are technical and
practical capable. A lot of attention must be
spending on the dilatations and the working joints
to avoid edge damage.
The Contec Ferroplan System is a highly sophisticated
system for renovation of constructions like
industrial floors, airport and harbour pavements
and both steel and concrete bridges and therefore
it is not possible to write all the necessary information
and all the different possibilities in one instruction
sheet. For special constructions and renovation
problems we ask you kindly to contact our
Technical Staff or a representative from Contec
ApS in your country.
In some cases, especially when the restrengthening
of constructions is an objective, it
will be necessary to consult a specialized engi
neering company to calculate the final strength
and strengthening effect from the Contec Ferroplan
System topping or overlay with the use of
advanced finite elements calculation programs.
WELDED MESH REINFORCEMENT
The placing, connecting and anchoring from the
welded mesh reinforcement is very important. The
welded mesh reinforcement should be supplied as
flat mesh in mats. De welded mesh reinforcement
must have a rebar thickness of minimum 6 mm and
a mesh size of maximum 50 mm. De welded mesh
reinforcement will be placed on distance keepers
and connected to the sub base by use of special anchors
or dowels. De distance between two connection
points is not allowed to be more than 750 mm.
When more layers of welded mesh reinforcement
are used they must be placed in such a way that
they are not exactly on top from each other and they
have to be well connected to each other. We recommend
to weld the reinforcement together in such a
way that they are fixed well. When a plastic foil is
used as membrane or when there is no surface
structure at all, than the maximum distance between
the anchors is not allowed to be more than 500 mm.
The maximum distance from the anchors with regards
to walls, banquettes, dilatations, etc. may not
be more than 100 mm. The welded mesh reinforcement
mats are not allowed to be placed on each
other but have to be placed in each other with a anchoring
depth 50 – 100 mm. A “non-bonded” Contec
Ferroplan System needs special preparations to
avoid friction from the sub base and therefore anchors
are not used. The distance between the surface
from the sub base and the underside of the first
rebar’s from the welded mesh reinforcement must be
minimum 6 mm. The cover on the rebar’s in the top
should be minimum 6 mm after placing the Contec
Ferroplan mortar.
MIXING
Contop N 85-4 is supplied in two or three components:
Contop B7 in 25 kg bags or Contec Binder N
in 25 kg bags, Contop B9 in 40 kg bags and Contop
B7 in 25 kg. bags. Delivery in Big Bags or as Bulk is
possible. Steel fibres are supplied in 25 kg bags or
boxes. It is highly important to use the exact amount
of mixing water.
CONTEC APS - Axel Kiers vej 30 - 8270 Højbjerg - www.contec-aps.dk
Tlf. +45 86 721 722 - Fax. +45 86 721 723 - e-mail: Info@contec-aps.dk

Steel fibre reinforcement: must be in principle
always used. In some cases, like for instance in
the food processing industry, where steel fibres in
the surface are absolutely not allowed a 15 mm
thick Contop N 85-4/ 95-4 topping can be placed
“wet in wet” above the rebar’s in the top. It will than
thus be necessary to work with two different mixes.
To mix the Contec Ferroplan mortar an efficient
paddle pan mixer of min. 300 litre must be used.
Buckets with a grade mark have to be used for the
measuring of mixing water. When steel fibres have
to be add an accurate balance will be necessary.
Add the mixing water to the Contec Ferroplan mortar
during mixing. Continue mixing for 5 minutes
until the material has a uniform consistency and
take care that also the material in the corners and
the bottom is mixed as well. Recommended is to
use several paddle pan mixers to secure a continuously
supply of mortar.
Recipe: see the last page.
LAYING
When the sub base is an absorbent sub base like
for instance concrete than it must be water saturated
but without free water on the surface. When
water saturation from an absorbent sub base is not
possible it must be sealed with a coating, asphalt
emulsion, plastic foil, etc..
Contec Ferroplan: Is usually applied in a thickness
from 25 – 40 mm with the use of one layer of
welded mesh reinforcement. Thicker layers are
used to re-strengthening constructions like
orthotropic steel bridge decks and viaducts but
also floors in cold stores, freezing tunnels, etc.
Special reinforcement principles can be designed
for non standard applications. The standard recipes
are mentioned at the last page.
For this it will be necessary to use firmly fixed guiding
rails from U or L profiles or to use “skies” or
runners under the double beam vibration screed.
The mortar is spread evenly over the surface from
the sub base. Hereafter the mortar is screed of and
compacted with a double beam vibration screed.
The double beam vibration screed must be adjusted
in such a way that the vibrations are not to
heavy or to light: high frequency - low amplitude.
The double beam vibration screed is moved slowly
with contact to the guiding rails and with constant
surplus of mortar over the entire length of the
screed to avoid unevenness. In places which are
to difficult to reach with the screed a small vibration
float or a poke vibrator must be used. When the
guiding rails are removed the grooves must be refilled
with mortar.
FINISHING:
After having obtained a well compacted and even
top layer the finishing procedure can start. The
finishing procedure will start with a power float with
a closed disk to close the surface from the Contec
Ferroplan mortar. Hereafter, depending on the desired
final surface structure, the surface can be
finished with the power troweling machine with
combination blades and/ or finishing blades. A very
smooth surface can than be obtained.
CURING
To avoid evaporation from mixing water it is necessary
to cure the surface from the Contec Ferroplan
topping immediately after finishing the surface. This
can be done by use of applying an equal layer of
Contec Curing Compound (minimum 100 gr/m²) or
by covering the surface with a plastic sheet and water.
When the Contec Ferroplan topping will be
coated than we recommend the use of plastic sheets
as a curing.
JOINTS
If necessary that the joints in the base concrete has
to be reflected in the topping. The use of a joint filler
and the type of joint filler will depend on the mechanical-,
chemical- and thermal loads and other
requirements in reference to for example the fluid
tightness of the topping.
CLEANING
Tools and equipment must be cleaned with water
before setting of the Contec Ferroplan mortar commences.
HEALTH AND SAFETY
Contop cementious systems are non-toxic and safe
to use, however, powder in contact with water or
moisture produce a strong alkaline
solution. Protective gloves, clothing and a dust mask
should be worn when mixing and applying the material.
DOCUMENTATION
For more information and the technical specifications
of the Contec Ferroplan System we refer to the next
documentation:
Technical Data Contec Ferroplan System.
Contec Technology for Industrial floors: The Contec
Ferroplan System.
Contec Technology for Cement based mortars.
Safety Regulations for Contec Cement based mortars.
CONTEC APS - Axel Kiers vej 30 - 8270 Højbjerg - www.contec-aps.dk
Tlf. +45 86 721 722 - Fax. +45 86 721 723 - e-mail: Info@contec-aps.dk

MIXING INSTRUCTIONS: The following mixes can be considered as standard for thin layers with reinforcement
Ø 6 mm. Any variations in reinforcement principles, layer thickness, etc. must be carefully considered
and discussed with your local Contop agent or our office.
Contec Ferroplan System:
Consistency: Half plastic
Layer thickness :
Contec Binder N
Contop B9
Contop B7
Water
Steel fibres
Amount of material:
Single reinforcement
25 - 40 mm
25,0 kg
40,0 kg
62,5 kg
8,4 –8,8 kg
4,5 kg
52,0 litre
ADDITIONAL INFORMATION: All technical information contained in our literature or otherwise transmitted, is given in good faith,
based on test data and experience. Whilst normal handling and application techniques associated with cementitious materials should
be observed, we are pleased to give advice on particular applications and site conditions. however we can not be responsible for any
loss or damage arising from individual site conditions or methods of application beyond our control. PBU 27.07.2001
CONTEC APS - Axel Kiers vej 30 - 8270 Højbjerg - www.contec-aps.dk
Tlf. +45 86 721 722 - Fax. +45 86 721 723 - e-mail: Info@contec-aps.dk