Properly Place Decorative Concrete Overlays in Extreme Weather Conditions

TRU PC Floor by National Concrete Polishing

Indoors and out, decorative concrete overlays permanently cover up surface imperfections in existing concrete, giving them any new look imaginable at a much lower cost than removal and replacement.

Today’s cement-based overlays combine polymer resins with cement, sand, acrylics or acrylic blends and other additives to improve performance, wear resistance, beauty and shine. They adhere well to existing concrete and resist damage from salt, chemicals, UV exposure, freeze-thaw conditions and abrasion.

The most popular types of decorative concrete overlays include stamped and stained concrete, and the popularity of other types varies in different areas of the country:

  • Exterior knock-down finishes are popular in the Sunbelt regions
  • Hard-troweled interior microtoppings are popular in metropolitan regions

With many options available, you’re sure to find at least one system that offers the most variety in color and finish while meeting your requirements for durability, appearance, maintenance and cost. Contractors must pay critical attention to adequate surface preparation, the most critical factor to long-term performance. For this reason, they prefer mechanical surface preparation, which does a more thorough job with the same grinding equipment and diamond tooling used for polishing concrete.

How to Concrete for Decorative Overlays in Extreme Weather Conditions

Concrete experts like the Portland Cement Association suggest contractors employ hot weather concreting procedures if the ambient temperature is forecast to exceed 77°F. Hot weather, high wind velocity and low relative humidity force higher concrete temperatures, which in turn increase the water-cementitious materials ratio, resulting in lower strength and reduced durability. Concrete will not only set quicker; the high rate of evaporation can cause early-age shrinkage and cracking before concrete sets. Thermal cracking can occur from rapid temperature changes such as those from a hot day to a cool night.

4 Key Temperatures to Check

  1. Air or Ambient Temperature
  2. Concrete Substrate Temperature
  3. Materials Temperature
  4. Water Temperature

Knowing these temperatures and employing the installation guidelines described below will help ensure the desired results are achieved.

10 Installation Guidelines for Hot Weather Concreting

  1. Store materials in a cool, dry place, rather than on-site underneath a tarp, which can get very warm.
  2. Plan the installation early in the day, when both air and substrate temperatures will be at their lowest.
  3. Substrate temperature is most important. Use a surface thermometer to determine the deployment of hot weather concreting procedures. Tenting or shading the installation area can help control substrate temperature.
  4. Work the materials more quickly and in smaller areas. It is critical to use the right tools, including heavy-duty drills for mixing, to maximize efficiency. Providing sufficient labor will minimize the amount of time required to place and finish the materials.
  5. Make modifications to concrete mixtures. Adding retarders, water reducers, extended set-control admixtures, slag cement or synthetic fibers can reduce slump loss, setting time and plastic shrinkage cracking.
  6. For exterior applications, erect temporary wind breaks to prevent rapid evaporation due to air movement over the surface. Use sunscreens, mist fogging or evaporation retardants.
  7. Chill mix water and store aggregate in a cool, dry place. Blocks or bags of ice in a 55-gallon drum of water will chill the water to increase working time. In the case of a pump installation of a self-leveling material, sections of copper tubing or coiled garden hose packed in a drum of ice will chill the water on its way to the pump, also allowing for a longer working time.
  8. The mixing bucket or barrel must be cleaned before mixing a fresh batch of material. Leftover material on the sides of the mixing bucket or barrel can accelerate the set times of the materials.
  9. Consider using accelerators to expedite finishing operations and avoid plastic shrinkage cracking.
  10. Where possible, halt concrete work until the temperature is more conducive to a successful installation.

Runyon Surface Prep is a full-service stocking distributor for all your concrete prep, polishing, decorative, repair, restoration and maintenance needs. We carry the following:

CTS RAPID SET 50 POUND TRU SELF-LEVELING CEMENT – Use CTS Rapid Set TRU Floor Self-Leveling Cement for high performance floor topping, underlayment and resurfacing projects. TRU Self-Leveling is ideal for projects that require long life and working time. It settles to a light off-white color ideal for stained, dyed or decorative aggregate flooring. Not only can TRU grind, but it can also be used to polish, making it ideal for those shiny decorative floors.

CTS RAPID SET 50 POUND TRU GRAY SELF-LEVELING – Use Rapid Set TRU Gray Self-Leveling when you need a high quality, fast, cement gray topping that can be polished. TRU Gray is a high performance, architectural topping and resurfacer that can be used indoors and outdoors, in wet or dry environments. It is ideal for projects that need long flow life and working time while achieving high early strength. A customized appearance can be achieved by adding decorative aggregate.

CTS RAPID SET 60 POUND TRU PC POLISHED CONCRETE TOPPING – Use Rapid Set TRU PC Polished Concrete Topping when you need your floor ready for foot traffic in 2 to 3 hours. It is a professional grade, hydraulic cement-based, self-leveling topping that can be ground and polished to expose the aggregate and simulate the appearance of polished concrete. TRU PC levels rapidly, maintains workability for up to 20 minutes, produces a dense surface, and has high bond strength. As an interior and exterior product, TRU PC is durable in wet or dry conditions.

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The Time is Now to be OSHA-Ready for New Crystalline Silica Rule

The Occupational Safety and Health Administration (OSHA) has issued a final rule to curb lung cancer, silicosis, chronic obstructive pulmonary disease and kidney disease in America’s workers by limiting their exposure to respirable crystalline silica.

The new OSHA regulation, Respirable crystalline silica, Section 29 CFR 1926.1153, took effect on June 23, 2016. Industries have one to five years to comply with most requirements, based on the following schedule:

Construction – June 23, 2017, one year after the effective date.

General Industry and Maritime – June 23, 2018, two years after the effective date.

Employers who fully and properly implement the engineering controls, work practices and respiratory protections are not required to measure respirable silica exposures to verify levels at or below the PEL for workers.

For contractors, this means now is the time to make sure your equipment will comply.

OSHA Enforcement Table

(Fine information supplied from Contractor Supply Magazine)

About 2.3 million workers are exposed to respirable crystalline silica in their workplaces. This includes 2 million construction workers who drill, cut, crush or grind silica-containing materials such as concrete and stone, and 300,000 workers in brick manufacturing, foundries and hydraulic fracturing.

Who Is Affected?

Anyone working on a construction site who creates or is exposed to silica dust in the course of performing work, including, but not limited to:

  • Grinding
  • Drilling
  • Barrel mixing
  • Edging
  • Cutting block
  • Sweeping
  • Shot blasting
  • Hand Grinding
  • Scarifying
  • Drywall sanding
  • Demolition
  • Precasting
  • Bricklaying
  • Broom sweeping

Key Provisions of the New Crystalline Silica Rule

  • Reduces the permissible exposure limit (PEL) for respirable crystalline silica to 50 micrograms per cubic meter of air, averaged over an 8-hour shift.
  • Requires employers to use engineering controls (such as water or ventilation) to limit worker exposure to the PEL; provide respirators when engineering controls cannot adequately limit exposure; limit worker access to high exposure areas; develop a written exposure control plan, offer medical exams to highly exposed workers, and train workers on silica risks and how to limit exposures.
  • Provides medical exams to monitor highly exposed workers and gives them information about their lung health.
  • Provides flexibility to help employers — especially small businesses — protect workers from silica exposure.

New Exposure Limits

New Silica Exposure LimitsChanges to the Permissible Exposure Level (PEL) of respirable crystalline silica is 50 micrograms per cubic meter of air (50μg/m3) at an 8-hour, time-weighted average (TWA) under any foreseeable conditions. The Action Level (AL) is 25 ug/m3 (0.025 mg/m3). You are at risk if the dust you breathe during an eight-plus-hour shift contains more RCS than the accessible amount, which is much smaller than a penny. 

How to Choose a HEPA Vacuum

  • High quality HEPA filters that are tested and certified, with a rating of at least 99.99 at 0.3 micron
  • 25 CFM per blade is required for hand grinders
  • High CFM & Water Lift for proper matching to equipment
  • Must have a mechanical filter cleaning method that is contained and allows no dust to escape
  • Multi levels of filtration, including a cyclonic chamber, pre-filters, HEPA’s and pre-separators
  • Drop down bagging containment systems, no dust can or tray
  • Availability to attach tools for collection at the source
  • Wet and dry availability when needed

For an in-depth look at the new regulation, read our blog, The New Crystalline Silica Rule – Are You OSHA-Ready?

Runyon Surface Prep is a full service stocking distributor for all your concrete prep, polishing, decorative, repair, restoration and maintenance needs. We carry the full line of Ermator vacuums and pre-separators, as well as grinders, removal equipmentoverlay productscolor products, densifiersmixersdiamond toolingpolyasparticsjoint fillers and much more. You name it, we have it!

Contractors Get Big Advantage with Section 179: Fast Facts on How Buying Now Can Expand 2017 Business

Have you ever wished you could buy new equipment to grow your business and also help your bottom line? The Section 179 deduction allows for businesses to deduct the full amount of the purchase price of equipment up to $500,000, as long as the equipment is purchased before the end of December 31, 2016.

Fast Facts:

  • Section 179 is aimed at general business equipment. If you plan to use the equipment you are leasing, financing, or buying for business purposes in 2017, then it most likely qualifies for a Section 179 deduction.
  • Section 179 deductions are simple to handle. Simply buy, lease, or finance your equipment and fill out IRS form 4562.
  • Section 179 is a “Use- It-Or-Lose-It” write-off that ends on the 31st of December, so it makes sense to utilize the tax savings while you can.
  • Section179.org offers a calculator where you can estimate your savings on qualifying equipment.
  • The equipment you write off for Section 179 must be bought in the tax year in which you are claiming the deduction.

Reasons to Buy Now:

  • Expand your services in 2017 to offer coatings, decorative concrete and polished concrete by investing in the right equipment to do the job
  • CPS Grinders, burnishers, auto scrubbers, and vacs, including electric or propane versions, qualify for this deduction
  • CPS is offering incentives and special deals during the end of the year, so you can increase your savings even further on equipment.

Taking the Section 179 deduction is a straightforward way to invest in the future of your business while saving a bundle. Why not take advantage of the opportunity to grow your contracting business with CPS grinding and polishing equipment? Through December 31st, customers with qualifying equipment purchases through Runyon, a CPS distributor, will receive a $250 Amazon Gift Card AND a $250 credit towards CPS tooling.

Be sure to talk to your tax advisor to learn more.

To take advantage of this special offer, contact us here or for more information, download the PDF info sheet here.

Contractors Get Big Advantage with Section 179: Fast Facts on How Buying Now Can Expand 2017 Business

About Concrete Polishing Solutions

Concrete Polishing Solutions is the leader in providing equipment, tooling, chemicals, and training to contractors and distributors in the polished concrete flooring industry. CPS offers a full line of equipment, tooling, and chemicals for all of your polished concrete needs. From start to finish, CPS helps you save time and earn more. More information on Concrete Polishing Solutions can be found at our website www.go2cps.com.

[VIDEO] How to Install Sparta-Chip in a Residential Garage

HP Spartacote protective concrete coatings show superior levels of durability, flexibility, adhesion, corrosion resistance, and chemical resistance. All achieved by HP Spartacote’s high level of knowledge of coating chemistry and the ability to focus on customers needs. HP Spartacote’s moisture cure coating chemistry enables them to formulate products that are not only applicable regardless of the climate but also designed to dramatically reduce application times and costs. They perform far superior with respect to traditional epoxy and urethane coating technology and are easy to install.

The HP Spartacote line of coating products are ideal for garage floor coatings, industrial flooring applications, in commercial or retail settings, residential homes, parking garages, etc. The variety of application settings are vast due to HP Spartacote’s quick cure time, straightforward application process and strong and durable chemistry. Check out the video below to see the step-by-step installation process of one of the many HP Spartacote flooring systems – Flex PURE Chip in a residential garage application.

Here are the steps covered in this coatings installation:

  1. Prep the surface to an ICRI CSP 2 by mechanical grind.
  2. Mix two part Spartacote Flex PURE pigmented material together with a slow speed drill.
  3. Pour a ribbon of material and spread using a Spartacote broom.
  4. Backroll the resin in a perpendicular fashion.
  5. Following the backroll, broadcast chip to refusal. Allow the chip broadcast coat to cure.
  6. Remove excess chip by broom and retain for another project.
  7. Scrape the surface smooth, working in three directions. Discard the excess chip. And blow the debris from the surface.
  8. Mix two part Spartacote Flex PURE top coat.
  9. Apply a ribbon of material onto the surface and broom the resin.
  10. Backroll the PURE top coat in a perpendicular fashion.
  11. The surface is ready for foot traffic in two hours and ready for vehicle traffic in 24 hours.

To learn more, go to the HP Spartacote website: hpspartacote.com. For purchasing and ordering questions, visit Runyon Surface Prep. We’re a premier distributor that carries the full-line of products, provides service and support and will go above and beyond to meet your needs. Contact us for more information.

Build Fast, Build to Last with Rapid Set Cement Products

High-gloss polished concrete with more clarity using the Rapid Set® TRU Flooring System.

CTS Cement Manufacturing Corporation has an extensive history of providing innovative, high-performance cement products to the construction industry. CTS manufacturers Rapid Set® professional-grade cement products made with Rapid Set® cement, a calcium sulfoaluminate (CSA) cement technology. These products are engineered for high performance, versatility, low shrinkage, and rapid strength gain – performance characteristics that allow contractors to save significant time and money, with reduced installation times, labor requirements, and long-term operations and maintenance costs. Rapid Set gains structural strength in one hour. And contractors can build faster, quickly put the structure or area into full service, while achieving durable, long-lasting results. Rapid Set has been used on notable landmarks like the Hoover Dam Bypass, the Pentagon, the Lincoln Tunnel, the San Francisco-Oakland Bay Bridge, as well as major roadways, airports, commercial and industrial projects worldwide. Rapid Set has grown to more than 50 specialized cement products for new construction, restoration and repair needs – including the TRU Architectural Flooring System which includes TRU Self-Leveling and TRU PC Polished Concrete.

CTS Rapid Set TRU Sell Sheet

This handy one-sheet outlines the key information you need to specify these high performance architectural toppings, from pricing and uses to specs and application procedures, as well as supplies needed to get the best results possible.

Rapid Set TRU Self-Leveling

Use TRU Self-Leveling as a high performance floor topping, for underlayment and resurfacing projects or for all three. Ideal for projects that require a long working time as well as a long life, TRU can both grind and polish stained, dyed, shiny or decorative aggregate flooring.

Mix a 50-pound bag with water. The cement can be applied at a minimum thickness of 5/16-inch, with an average of 3/8-inch. When making repairs less than 6-inches by 6-inches:

  • free the area of loose debris
  • clean the area completely
  • wetting the area and blow away any residual water
  • tape around the area so no TRU cement gets on the polished concrete
  • mix the TRU product “really wet” – you want a lot of the sand, not the cream
  • pour it over the area, a little higher than the rest of the floor to make sure that when you grind it off, you’re cutting down to the sand

TRU PC Polished Concrete Topping

Use Rapid Set TRU PC Polished Concrete Topping as a topping, resurfacer or underlayment. This versatile product is a professional grade, hydraulic cement-based, self-leveling product that can be ground and polished to expose aggregate, simulating the appearance of polished concrete. Delivering outstanding clarity and gloss, you can create a variety of design possibilities by incorporating colors and aggregates.

TRU PC maintains workability for up to 20 minutes and is ready for foot traffic in two to three hours; coatings in 12 hours; and grinding and polishing in 24 hours. It produces a dense surface with high bond strength, is durable in wet or dry conditions, and can be used inside and out.

When making repairs less than 6-inches by 6-inches, follow the same instruction as TRU Self-Leveling.

The New Crystalline Silica Rule – Are You OSHA-Ready?

As of June 23, 2016, a new OSHA regulation, Respirable crystalline silica, Section 29 CFR 1926.1153, is being implemented and enforced. This regulation builds upon the Occupational Safety and Health Administration’s National Emphasis Program on Crystalline Silica, which has been in effect since January 24, 2008. In addition to updating Permissible Exposure Limits (PELs), it sets forth stricter regulations on the contractor, demanding greater dust collection on the job site. (Click here to review the new ruling).

The Problem: Hazardous airborne dust in the industrial and construction industries.

The Solution: Engineered dust control through vacuums, air scrubbers and point-of-origin accessories.

“Equipment manufacturers, contractors and regulatory boards all need to work together to make work areas safer,” says Fredrik Akermark, VP of Sales and Marketing for Ermator USA. “With new PEL ratings for the construction industry, we all need to be pro-active in dust control.”

Concrete & Masonry Dustless Tool Systems

Dust Suppression in the Work Place

Contractors in all industries are now compelled to outfit tools and machines with dust containment equipment such as shrouds and vacuums. Manufactures of equipment in the concrete, masonry and stone industry are incorporating dust suppression systems into their equipment. These measures:

  • Control airborne dust that is harmful to breathe
  • Reduce labor on dust clean-up as it settles
  • Protect workers at the job site
  • Increase safety of employees and customers if the building is open during construction work

Hazards of Concrete Dust

Crystalline silica is a basic component of soil, sand, granite and many other minerals. Quartz is the most common form of crystalline silica, as well as Cristobalite and tridymite. All three may become respirable sized particles when workers chip, cut, drill or grind objects that contain crystalline silica. Crystalline silica has been classified as a human lung carcinogen and silica exposure remains a serious threat to nearly two million U.S. workers, including more than 100,000 workers in high risk jobs such as abrasive blasting, foundry work, concrete, rock and stone cutting, coring and drilling, quarry work and tunneling. Exposure can increase the risk of developing silicosis, lung cancer, tuberculosis and other debilitating diseases. The respirable silica dust enters the lungs and causes the formation of scar tissue, thus reducing the lungs’ ability to take in oxygen. Public health experts estimate that 280 workers die each year from silicosis – and thousands more develop silicosis as a result of workplace exposures. There is no cure for silicosis.

Features to Look for When Selecting a Vacuum

  • High quality HEPA filters, that are tested and certified
  • Multi levels of filtration that includes pre filters and pre separators
  • Contained filter cleaning so as not to allow dust to escape when cleaning filters
  • Proper Cubic Feet/Minute (CFM) and water lift for the tool its being attached to
  • Accessory availability to install on the tool for collection at the source and floor tools for clean-up
  • Auto tool features so as soon as the tool starts the dust control is activated
  • Wet and dry availability when needed based on job site conditions
  • Control of dust when changing bags with drop down systems

Pullman Ermator Vacuum Line Dust Extraction Equipment

OSHA Recommendations

  • Replace crystalline silica materials with safer substitutes, whenever possible.
  • Provide engineering or administrative controls, where feasible, such as local exhaust ventilation, and blasting cabinets.
  • Installing dust collection systems on to machines or equipment that generates dus.t
  • Use all available work practices to control dust exposures, such as water sprays.
  • Wear only a N95 NIOSH certified respirator, if respirator protection is required. Do not alter the respirator. Do not wear a tight-fitting respirator with a beard or mustache that prevents a good seal between the respirator and the face.
  • Wear only a Type CE abrasive-blast supplied air respirator for abrasive blasting.
  • Wear disposable or washable work clothes and shower if facilities are available. Vacuum the dust from your clothes or change into clean clothing before leaving the work site.
  • Check filters hoses, shrouds and connectors when using dust control equipment to capture all particles from escaping.
  • Participate in training, exposure monitoring, and health screening and surveillance programs to monitor any adverse health effects caused by crystalline silica exposures.
  • Be aware of the operations and job tasks creating crystalline silica exposures in your workplace environment and know how to protect yourself.
  • Use water attached to equipment to control dust.
  • Be aware of the health hazards related to exposures to crystalline silica. Smoking adds to the lung damage caused by silica exposures.
  • Do not eat, drink, smoke, or apply cosmetics in areas where crystalline silica dust is present. Wash your hands and face outside of dusty areas before performing any of these activities.

Pullman Ermator for New OSHA Regulation Compliance

Conventional vacuums don’t collect the hazardous silica dust to pass the new OSHA standards. Ermator dust extractors, air scrubbers and point-of-origin accessories help you comply in meeting OSHA’s new regulations. Ermator vacuums feature tested and certified HEPA filters, the highest CFM and waterlift in their class, Longopac collection system and mechanical JetPulse filter cleaning.

Runyon Surface Prep is a full service stocking distributor for all your concrete prep, polishing, decorative, repair, restoration and maintenance needs. We carry the full line of Ermator vacuums and pre-separators, as well as grinders, removal equipment, overlay products, color products, densifiers, mixers, diamond tooling, polyaspartics, joint fillers and much more. You name it, we have it!

Surface Profile Inspection Guide from SP1 to SP10

A surface profile of concrete or asphalt is a number associated with the material’s desired roughness or texture and its general appearance. It helps in determining if the surface is fit for a specific purpose. Roughness can be an indicator for:

  • Wear-ability
  • Friction coefficients
  • Performance in terms of cracks or corrosion
  • Adhesive properties

Our Surface Profile Inspection Guide helps in determining the desired surface profile of your concrete or asphalt and indicates the proper diamond tooling and machinery required for achieving it during the preparation process.

Surface Profiles (SP1-SP10)

The lower the surface profile (SP) number (SP1), the flatter the surface. An SP10 rating is an extremely rough surface. An accepted definition of surface profile is “the average distance from the peaks to the valleys of the surface, as seen through a cross-section of the prepared substrate.” The range of variation with your specific concrete slab, substrate or asphalt depends on its strength, composition, aggregate and finish. The final surface must allow for the secure mechanical bond of any sealer, coating or marking material, so make sure the surface is free of any dirt, oil, films, paint, coatings, cure, sealer and any other material before creating your desired surface profile.

Runyon Surface Prep carries a full line of HTC, Husqvarna, and CPS grinders, Edco scarifiers and scabblers, National floor scrapers, diamond tooling, carbides, scrapers and shot blasters for use in surface preparation.