The PORTAMIX MEGA HIPPO® – New Innovation For Faster On-Site Mixing and Pouring

New CS Unitec MEGA HIPPO MixerMuch of the effort and energy it takes to mix and pour cement, grout, mortar, texture coatings, sealants, adhesives and other self-leveling compounds can be alleviated by using a portable mixer such as a HIPPO mixer from CS Unitec. Now, you can further reduce your crew’s physical effort while boosting productivity and lowering labor costs with the newest portable mixer model.

Mix, transport and pour products even faster — and more easily — with the recently introduced PORTAMIX MEGA HIPPO® Mixing Station:

  • Mix, transport and pour up to six 50-lb bags in minute
  • One operator can accurately place material directly onto the floor
  • Mix in bulk and dispense into smaller containers
  • Excellent mix consistency and easy blend

How did a great mixer like the HIPPO get even better? The new MEGA HIPPO liner canister system makes quick work out of mixing multiple batches. The “Easy-roll Trolley” and the balanced “Easy-tilt Cradle” let you pour and spread material at the same time, eliminating multi-stage pours. Wheel covers keep casters free of screed splatter. Additional features:

  • Standard equipment includes mixing, motor, bucket, removable liner and two paddles
  • Specially shaped mixing bowl eliminates pockets of unmixed product
  • Full-brim capacity of 23 gallons or 350-lbs
  • Two 9″ diameter paddles with helix ribbon and side bars thoroughly mix colors and additives quickly
  • High-torque, 15 Amp, 2-geared motor
  • Liners are pliable and easily cleaned; alternating liners prevents cross contamination
  • Dust extraction port for vacuum connection

If you want to upgrade your concrete and cement mixing machines or portable mixer stations, Runyon Surface Prep carries a full line of CS Unitec concrete HIPPO mixers, paddles and hand grinders for all your surface preparation needs, including the new Portamix MEGA HIPPO model.

Applied Flooring’s Polished and Colored Concrete Success in Troy, MI

Last week one of our customers, Applied Flooring, had a job in Troy, MI at a Nordstrom store. Along with the Applied crew, the Nordstrom GC and technicians from CTS Rapid Set and Metzger/McGuire helped complete this floor. Below are the before pictures, showing the extensive structural damage. Because of so many cracks breaking up the surface, the crew wasn’t able to polish first thing. Instead, the first step was filling the cracks. Then, once the concrete floor was repaired, an overlay was applied, the control joints were cleaned and recut and the concrete was colored. Below you can see the process from initial pour to finished look.


Concrete Overlay and Color Application

Applied Flooring used CTS Rapid Set’s TRU self-leveling overlay on the floor, and colored it with AmeriPolish OS dye. The crew worked in 20-degree weather and wrangled both the water and pump hoses from outside in the parking lot up a flight of stairs to the work area. The 300′ water hose and 400′ pump hose were at their maximum lengths. Applied made it work though, and after the overlay was laid they moved into the color application stage.

One of the biggest takeaways from this particular job revolved around the importance of color intensity. Initially, OS integral color was used, but the pigment wasn’t strong enough, so the dye was applied after the fact to accommodate the time-sensitive nature of this project and to best utilize resources.

Below you can see the floor after the second pour of TRU, the floor after 3DHS densifier was applied and finally, the polishing stage.


The Finished Look

Although there were a few unexpected surprises throughout this process, as is common with any job, Nordstrom was incredibly satisfied with the final polished floor. You can see below how reflective and high-end this space appears, especially after the merchandise was moved back in.

 

As always, if you have any questions about the products or the processes used for this particular job, please feel free to reach out via our website or in the comment section below. We would love to hear from you! And if you ever need additional support at a job, feel free to reach out to our technical support team and we will assistant in any way possible, even if it means flying to you!

A Decorative Concrete Success at World of Concrete 2014

World of Concrete was a huge success this year! Our concrete slab came together really well with the help of our manufacturers and customers. It was a 5 day process to complete all the steps — applying the epoxy, laying the terrazzo, applying the overlay, grinding and polishing, applying intricate stencils and protecting and sealing the surface. With this said, we would love to give you insight on how we accomplished this feat. See the photo gallery below for the final result, and continue reading for more information on products used. Also, check out our YouTube channel for step-by-step videos.


Theme Inspiration

The Super Bowl/football theme for this year’s World of Concrete booth was the brain child of both Wendy Runyon-Ricker and her brother Jack Runyon – figureheads in the company, and creative ones at that. The idea initially stemmed from a general football field slab to the incorporation of Super Bowl team logos in the middle of the slab, then to the tailgates, and from there the featured customer hall of fame stories and booklet, all the signage, etc.

Products Used During Each Step of the Process

Epoxy Overlay:

Concrete Overlay:

Grinding and Polishing:

Stencils:

Protecting and Sealing:

Our Featured Artist: Floormap Stencil Designs

As mentioned, Floormap Stencil Designs did the Seahawks and Broncos stencils in the middle of our slab, and they did a fabulous job! Each stencil was three layers — making for an incredibly intricate pair of logo designs. Rachel Bruce is the artist who designed the custom stencils, and she was the one who actually applied them at World of Concrete.

It has been an exciting year for Floormaps as it enters its fifth year in the decorative concrete industry. It has tackled new products, such as vinyl stencils, as well as new surfaces i.e. polished wood floors, walls, ceilings, murals, banners and signs. New training courses will be issued quarterly to demonstrate the wealth of knowledge accumulated from hands on installations and experimentation. Floormaps is also proud to announce the opening of international sales to Europe, Asia, the Middle East and South America.

Be sure to check out the photo gallery on our website as well, which has pictures from the whole event. Also, be sure to watch the videos on our YouTube channel. And, if you never saw the customers we featured in our hall of fame, find their stories here. We hope to see you next year!

Rejuvenating JCPenney’s Floors to Polished Concrete Perfection

Retail stores receive a large amount of foot traffic, which inevitably means their concrete floors wear down and the quality of them diminishes over time, especially if not maintained properly. Such was the case at a JCPenney store in Madison, WI at the West Towne Mall. Thus, Hunter Advanced Concrete Polishing was tasked with rejuvenating the concrete floors to their former polished glory.

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What They Did

First the Hunter ACP crew shaved the floor to rid it of the tile that was previously covering the surface. As evidenced in the slideshow, the concrete underneath was in really rough shape. After removing all the tile, epoxy was poured and spread, then sand was broadcast over top to rejection. The next day all the sand was swept off and RapidSet TRU was mixed with AmeriPolish integral color in a CS Unitec Hippo mixer and poured and spread using spiked shoes and a porcupine roller. The floor could be walked on after 4 hours, but it is ideal to wait until the next day before grinding and polishing. After polishing to at least an 800 grit, the floors were shiny enough to protect and seal (the final step). You can see the finished result at the end of the slideshow — it looks much better now!

What Products They Used

If you have additional questions or comments, please let us know by contacting one of our Runyon Surface Prep team members, or utilize the comment section below. And for more customer highlights, visit our featured stories page.

Cuviello Concrete’s Exemplary Custom Home Overlay

Decorative concrete is a growing industry, with prevalence not only in commercial and professional settings, but an engrained presence in the residential home market as well. It’s fascinating to see the creative ways homeowners incorporate concrete into their living spaces in new and unique ways. Cuviello Concrete and Terrazzo Polishing has tapped into this industry trend, and a recent custom home polished overlay perfectly exemplifies why.

Products Used:

Job Completion Process:

This custom home overlay covers an area of 2,000 square feet of TRU self-leveling. Initially, 3/8″ of uncolored TRU was applied with SpiderLath. The second pour comprised 3/8″ of integrally colored TRU with 16-gauge zinc strips. The zinc strips marked off areas of the floor to be kept empty, as evidenced in the radiator picture above.

After mixing, pouring and spreading the TRU self-leveling overlay, the Cuviello crew used a grinder to polish the floor to its desired shine. They started with 50 grit metal-bonded Calibra ceramic discs and then worked up to 100 and 200. 3DHS densifier was applied to make the TRU denser. This densifier penetrates deep to improve surface performance and resist the harmful effects of traffic wear and weathering. After the ceramic discs, the crew used 200 and 400 V-Harr premium polishing pads.

The final step in the process was to protect and seal the floors with AmeriPolish SR2 stain resistor to preserve the floors for long-lasting shine and stain resistance.

Expert Tips:

  • Expect the unexpected, working in broken up areas will add 2-4 times the amount of labor depending on the general layout of the area
  • Educate, educate, educate the architect, owner and general contractor, then manage expectations

Major Successes:

This custom home job turned out gorgeous, but there were two big accomplishments that the Cuviello Concrete crew is especially proud of: finishing the edges to a zero tolerance without damaging the powder-coated window frames and pouring the second lift of TRU to exactly the top edge of the aluminum sliding window track and floor registers.

If you’d like to see more work from Cuviello Concrete and Terrazzo Polishing, see this previous post. For more information about this job (how it was accomplished, the products used, etc.) please don’t hesitate to contact us. And stay tuned for more customer highlights!

A Green Endurance Process Success with Cuviello Concrete

Cuviello Concrete - Howard County Middle SchoolCreating a polished concrete surface that is going to last over a long period of time, with little wear, long-lasting never-ending shine and well-preserved design is of course the ultimate goal for any polished concrete floor. However, actually attaining this is a different story. A unique concrete polishing solution, that addresses all of these desired outcomes, is the Green Endurance Process. This is a natural, yet customizable, approach with a focus on maximum durability and aesthetics. The process begins by working closely with architects to write in specs that are most conducive to the polishing process, eliciting the best results possible. Cuviello Concrete and Terrazzo Polishing is a large proponent of this process and integrates it into every job.

Recently Cuviello completed concrete polishing work at Howard County Middle School in Hanover, MD – a 23,250 square foot area. The corridors and cafeteria floor now feature cream and sand aggregate with multiple colors of dye in an elaborate design. What a head-turner! By using the Green Endurance process every aspect that effect the finished floor was controlled — mix design, placement, finishing, joint placement, the polishing process, protection and in service maintenance training.

The Green Endurance Process

  • Saw cut the pattern into the concrete
  • Fill the cuts with VersaFlex polyurea
  • Grind with 50 grit and 100 grit metal, 50 resin bond abrasive
  • Hone with 100 and 200 grit
  • Dye the floor with AmeriPolish Solvent Base Color
  • Densify the floor with Retro Plate 99
  • Finish honing with 400 grit resin bond abrasive
  • Polish with 800 and finally 1500 grit resin bond

Each bonded abrasive was fully refined from one grit to the next. At no time was any grit skipped.

Things to Keep in Mind

  • Understand exactly what the spec says and exactly what your scope of work includes and does not include
  • Educate, educate, educate your architect, owner and general contractor, and then manage expectations
  • Develop a TIGHT relationship with the division 3 contractor  be sure they understand what they are finishing is going to become the finished floor. Educate them beyond what the division 3 spec says and what is included in their scope of work.

Shining Moments

  • Successfully applied dye within the lines
  • Intricately saw cut the designs
  • Kept a consistent and steady work flow to accomplish saw cutting, joint filling, dying, densifying and polishing through multiple smaller crews

Get to Know Cuviello Concrete and Terrazzo Polishing

Cuviello Concrete and Terrazzo Polishing uses its expertise and experience with technical stone polishing to obtain maximum clarity of reflection (DOI Distinction of Image) and superior durability of the polished surface when applied to concrete and terrazzo. As a leader in the industry on an international level, expertise in contracting services places them in a unique position where they consult with and have trained other polishing contractors from across the globe. In addition, Cuviello Concrete was a founding member of the Concrete Polishing Association of America.

Glass + Concrete Overlay: A Colorful and Dynamic Combination

Glass AggregateShiny, yet bland concrete floors are not suitable for every business, which is why the trend toward decorative concrete flooring is so prominent. Decorative concrete is especially helpful for company branding purposes, or to make a bright and impactful statement in an indoor or outdoor space.

One of the main ways to achieve a colorful and dynamic polished look is by incorporating glass into concrete overlay. There are two recommended methods with which to accomplish this – either by mixing integrally or by broadcasting. And throughout both processes, it is recommended you use CTS Rapid Set’s TRU Self-Leveling overlay, glass from American Specialty Glass, integral color from Ameripolish and CS Unitec’s HIPPO Porta-Mix.

Mixing Integrally

For the first option, it is recommended you mix the overlay initially. If you are using Ameripolish’s integral color, the water and dye are mixed together before the overlay material is added. Next, screen the product with a 1/8” classifier to remove any unmixed material or clumps. Lastly, mix the glass with the overlay. This technique is ideal for a 50% load using size 0 or size 1 glass. You want to use smaller glass because then it has a better opportunity to stay close to the surface when placing it on the floor.

In terms of the finishing technique, you can generally gauge the rake depth at 3/8” depending on the load. Be sure not to use a spiked roller – it would only succeed in pushing the glass around. Rather, for mixing integrally, the preferred finishing method is with a smoothie.

Broadcasting Glass

Glass-Infused Concrete OverlayChoosing to broadcast is a much more delicate process than mixing integrally, the primary reason being that this option really depends on the set time of the overlay. If you throw the glass too early, it will all sink to the bottom, meaning it isn’t visible. Conversely, if you wait too long, the glass will sit on the surface, not penetrating, and could be pulled out of the overlay during the initial grind.

The size of the glass influences when to broadcast since the weight of the glass is relational to the size. You can use up to a size 2, but generally size 1 is best. If the glass is larger, thus heavier, then you should wait longer. Whereas, if the glass is smaller and lighter, then broadcast sooner. Again, keep in mind: this is a delicate process, so time this as accurately as possible.

When you do the initial grind, be sure to grind the surface enough to where there is not a void between the glass and the TRU – you want the two to bond or else the polish will be diminished. Also, be aware that when you broadcast, it is difficult not to have pull-out. We have used a grout coat from Husqvarna and Metzger/McGuire to fill the pit left behind when the glass is removed.

For the broadcast finishing process, here are the steps:

  1. Place the product
  2. Gauge rake to set depth
  3. Purge any air pockets with a spike roller
  4. Soon after the product begins to set, broadcast the glass

When you get to the third step, consider using a new porcupine roller on the market, one that Joe Zingale from CTS Rapid Set recommends. The spikes are stainless steel and are 1.25″ in length. The advantage to this new roller – it doesn’t leave spike marks in the TRU like plastic spike rollers do. This new metal roller has pin-like spikes, meaning they aren’t as thick.

Once the four-step process is complete, and the initial set of the overlay occurs, do not use a trowel or any other tool to press down glass that did not fully penetrate the overlay. Doing so will leave an impression, which could be difficult to get out.

Finished WOC Concrete FlooringThe Hybrid Approach

While not usually a common method, it is possible to combine the above two techniques into a hybrid approach. Meaning, you would first mix the glass integrally, and then you would broadcast after the product is placed. However, bear in mind that this is only effective with a load less than 50%.

This is really only a surface level understanding of the glass-infused concrete overlay process, and after mixing integrally or broadcasting the final step is grinding and polishing. If you would like to learn more about the next step, or how to implement the above listed techniques, then contact a Runyon Surface Prep sales rep, or for more on the products needed during this process visit the Runyon Surface Prep website. To view this post in its original article form, see the Concrete Decor post here.