TRU PC Polish Job by National Concrete Polishing & Grinding

National Concrete Polishing & Grinding out of Richfield, OH just completed a polish job in Madison, WI at the new Under Armour store. The National Polishing crew put down 8,000 square feet of TRU PC, a polishable overlay material from CTS Rapid Set. Check out the results. They polished this floor up to a 1,500 grit.

Rapid Set TRU PC Polished Concrete is a professional grade, hydraulic cement-based, self-leveling topping. It 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. TRU PC is ready for foot traffic in 2 to 3 hours. As an interior product, TRU PC is durable in wet and dry conditions.

National Concrete Polishing & Grinding Inc. uses the latest technology in polishing equipment and dust control systems, coupled with the highest quality diamond tooling to ensure they are meeting and exceeding their clients’ expectations. Customer Satisfaction and Loyalty are the life blood to National’s success, working closely with world class companies who entrust them to help improve their image. National also takes great pride in their image and reputation for running a clean, crisp operation, with uniformed employees, and logoed trucks.

Gorgeous Middle School Polish Job by Applied Flooring

Applied Flooring just completed a gorgeous polished concrete flooring job in Dearborn, MI at Woodworth Middle School. See the finished floor below…

 

The Applied Flooring crew wet cut with HTC metals and STI terrazzo pads. Then they polished the floor with STI FL-07 pads, densified, stained the floor with Ameripolish classic dye, guarded the floor with Prosoco LSGuard and burnished with STI Spin-1 pads.

About Applied Flooring

Applied Flooring, Inc. has been repairing concrete floors since the early 1970s. The company thrives on developing long-term relationships with repeat customers. The epoxy flooring profession has seen tremendous advancements over the last 50 years and Applied Flooring has always been at the leading edge of the industry. Applied Flooring’s knowledge in concrete resurfacing is extensive with qualified technicians and well-trained applicators.

The Advantages & Array of Diamond Tooling Options

Diamond tooling cuts into concrete and other surfaces using diamond grains that are bonded onto special parts of surface preparation equipment. Because the diamond is considered a super-hard material, diamond tooling has many advantages compared to tools made with common abrasives such as corundum and silicon carbide.

In addition, the concrete, rock or steel you need to cut into are also some of the hardest materials known to man. To cut through them with precision, you need something even harder. Diamond tooling fits the job.

Diamond Tooling Comparison Guide

We carry a wide array of diamond tooling for concrete surface preparation and concrete polishing available as private label and from leading manufacturers such as Husqvarna, HTC, CPS and STI. We’ve also created this quick-read, full-color Diamond Tooling Comparison Guide to help you choose the right diamond tooling for your job or project. Take a look:

Runyon Diamond Tooling Comparison Guide

Whatever level of finish you are looking for, we carry a full range of diamond tooling, including metal bond tools, hybrid transitional tools, resin tools and polishing pads. From the hardest concrete floor to the most porous, put these metal-bond diamonds, hybrids, resins and polishing pads under your concrete floor grinder (we also carry adapter plates to convert for your specific machine).

Whether grinding and polishing old or new concrete floors, our products combine advancements in the latest diamond technologies, planetary floor grinding equipment and floor treatment products that help you transform your floors into highly abrasion-resistant, incredibly dense, smooth and visually appealing surfaces.

Advantages of Diamond Tooling

If you need tools to get a slab ready for new VCT, epoxy, urethane concrete, carpet or concrete polishing, diamond tooling can offer a range of advantages:

  • High grinding efficiency, low grinding force: Less heat is generated by the hole in the grinding process, which decreases or avoids burns and cracks on the surface, the equipment’s wear and energy consumption.
  • High wear resistance: Diamond tooling’s change in dimension is small, performing with good grinding quality and precision.
  • Long lifespan, long dressing period: This can greatly increase the work efficiency, improve the work environment and decrease labor intensity.
  • Low comprehensive cost: Diamond tooling is designed to yield the best possible productivity and cost per square foot for the contractor, so that he or she has the best chance at being profitable on every job.

 

Successful Manufacturing Floor Restoration By Surface Solutions USA

Based on excellent references and an award-winning reputation, Surface Solutions USA tackles a total floor restoration and performs seamlessly.

Surface Solutions USA Client Case Study

One of our longtime customers, Surface Solutions USA, recently completed the total floor restoration of a new distribution center for Milwaukee, WI-based Joy Global, Inc., a worldwide leader in high-productivity mining manufacturing solutions. The entire 275,000-square-foot floor of the building, which is owned by marine surplus superstore Great Lakes Skipper, had severe potholes and several deteriorated areas at different elevations, requiring extensive surface preparation before laying new concrete and seamless epoxy to create a smooth surface that would allow Automated Guide Vehicles (AGVs) to glide across with ease.

“This project is one of our most ambitious to date,” says Steve Hess, President of Surface Solutions USA. “The floor was in very rough condition, but with the surface preparation equipment purchased from Runyon Surface Prep, combined with Surface Solutions’ expertise, our ability to rip out and pour concrete and our branded epoxy products, we achieved the goal of smoothing out the floor, so Joy Global’s AGVs can pick parts off inventory racks and ship them around the world.”

In just four weeks, Surface Solutions’ team prepared the huge surface using high-performance HTC planetary grinders to clear away the existing floor, repairing and patching with new concrete before smoothing it to perfection using the Surface Solutions Epoxy 181, 1811vp and 321 systems at 22 mil total thickness. In addition, the installation team applied the Joy Global corporate logo graphic to the floor, sealing it with clear epoxy for a permanent finish.

As a company, Joy Global places the highest priority on safety. Management can rest assured that their new distribution center operations – with a new flooring system installed by Surface Solutions USA – will meet this goal, ensuring every employee returns home without injury or incident.

ABOUT SURFACE SOLUTIONS USA
Surface Solutions is an independent industrial floor contractor specializing in seamless, polymer flooring systems utilizing the most trusted brands in the industry. From testing to consultation and complete installation services, Surface Solutions is your premiere source of non-toxic, safe and environmentally friendly flooring systems, offering turnkey installations using only in-house personnel. All installations come with a complete single source warranty.

The 3-Stage Concrete Grinding, Honing and Polishing Process

Concrete Grinding Honing & Polishing Process

Polished concrete has captured the imagination of architects, engineers, property owners, interior designers and general contractors for a little more than 10 years. The entire design process is a mix of technical know-how, industry experience and artistic expression that can make or break the result, depending on the skill level of the polisher and crew. A good polisher will not only complete the technical training for concrete polishing, he will educate the customer on the type of processing, the total time and the cost of completing the job successfully.

Three Stages, Multiple Steps

Polishing concrete is a progressive process that changes and refines an existing concrete surface to a desired finish. This process starts with grinding and moves to honing and polishing. Each stage requires a series of steps that use consecutively finer grit abrasives to work the concrete, enhancing its aesthetic beauty, while a densifier is applied and absorbed into the concrete, creating a chemical reaction that makes it more dense and hard.

Three Types of Densifiers

  • Sodium
  • Potassium
  • Lithium

Meanwhile, a polisher must take into account variables he can control – and variable he can’t-that can affect the success of the polishing process, especially with an existing concrete slab. If it’s known that the concrete is to be polished before it is poured, use a polishing-friendly mix design and floor flatness rating for a better end result.

Controllable Variables

  • Equipment
    • Weight, RPMs, Speed
    • Planetary movement – active or passive, direction
  • Abrasives
    • Configuration of the diamonds’ face/tread
    • Saturation of diamond grit
    • Hardness of diamond bonding
    • Time to switch abrasives
  • Densifiers
    • Type
    • Application time
  • Physical grinding, honing and polishing
    • How the concrete surface is cut
    • Clarity of the cut surface
    • Refinement of the concrete from one grit to the next

Uncontrollable Variables

  • Condition of concrete surface
    • PSI
      • Residential concrete is generally a low, 2,500 PSI, hand troweled concrete mix; does not polish as well
      • Commercial concrete is a higher 3,500 PSI, machine troweled concrete mix in the open areas; hand troweled in corners and tight areas; polishes better
    • Imperfections to remove
    • Surface flatness and levelness
    • Hand or mechanically troweled
    • Presence of coatings, glues or mastics
  • The concrete mix design
    • Types of admixtures, fibers and polymers used
    • Aggregate
    • Vibrated for air removal or not

It’s All About the Grit Sequence

Polishers are looking for a number of conditions during the grinding, honing and polishing process:

  • Clarity of reflection
  • Sheen
  • Shine
  • Depth
  • Uniformity and color of reflection

To grind, hone and polish a concrete surface to the maximum “clarity of reflection,” use a sequence of grit abrasives, moving on to the next finer grit only when the previous one has done its job. This will insure a clean, crisp look of the concrete surface at a 200-, 400- and 800-grit resin while achieving a maximum surface durability.

Different stages of processed concrete look different to the seasoned eye:

  • Grinding level – the degree to which the surface is cut
    • Cream
    • Salt & Pepper
    • Exposed Aggregate
  • The level of clarity of reflection of the cut surface
    • Honed surface stops at 200- or 400-grit resin
    • Semi-polished surface stops at 400- or 800-grit resin
    • Highly polished surface stops at 1,500- or 3,000-grit resin
  • Decorative enhancements
    • Coloring with integral, acid-stained and water- or solvent-based stains and dyes
    • Saw cut patterns
    • Engraving

Runyon Surface Prep is considered a “polisher’s paradise,” because of depth and breadth of equipment and products available, including Husqvarna, HTC, STI tooling and grinders, Ameripolish, PROSOCO, Convergent, Dayton Superior and more. If you have any questions about what to choose, pricing or how-tos, don’t hesitate to contact us.

3 Methods of Decorative Aggregate Exposure for Beautiful Polished Concrete

A growing trend in versatile, beautiful flooring solutions that can also last a lifetime is the use of polished concrete. To attain such visual aesthetics, contractors first look at the concrete itself.

Working with Concrete

There’s a time-honored adage about concrete, whether processed or not, that it is consistently inconsistent. Every single pour will be different from the next, with variations in color, cracking and overall flatness. However, the general goal is for the floor’s flatness to be as even as possible while pouring a new slab, as well as preparing the surface of an existing slab for finishing.

This being said, when pouring a new concrete floor, it’s a good idea to look at a polished finish as part of a total flooring system that includes 1) a concrete mix design, 2) curing, 3) a finishing method and 4) the actual polishing process. A concrete slab that’s poured with the polishing process in mind will greatly enhance the end result.

Working with existing concrete slabs, results are determined by the quality of the existing concrete. Color variations, contaminates, cracks, patterns left by previous floor covering, stains, nail holes, patched areas and flatness all affect the newly polished appearance.

3 Concrete Polishing MethodsThe polishing process usually includes grinding down the surface to reveal different levels of aggregate within the concrete or the addition of decorative aggregates, such as recycled glass, landscaping stone, nails, nuts, bolts, sea shells and others, seeded into the surface for decorative purposes. There are three common aggregate choices to consider when it comes to polished concrete floors:

1. Cream Polished or Surface Cream: the top layer of the concrete is made from troweled cement paste that contains the cement fines of the mix. Only 1/32 – 1/64-inch is removed from the slab surface, resulting in little or no aggregate exposure. This is a popular, economical style; the cream is the purest, most consistent in color, has the fewest imperfections and can be stained any color.

2. Salt and Pepper: the layer just below the cream made from fine aggregate – sand and very small stone that gives the concrete a “salt and pepper” look. To achieve this look, 1/64 – 1/8-inch of the cream is removed by grinding the surface, exposing small amounts of medium aggregate randomly throughout. The ideal time to start the grinding process is within 7 days of pouring the concrete slab, which helps to expose just the right amount of aggregate.

3. Exposed Aggregate: the layer below the cream and salt and pepper made from coarse aggregate within the concrete mix. To reach this layer, 1/8 – 1/4 -inch is ground from the surface, removing the top two layers. This process should start almost immediately after a concrete slab has been poured to within 3 days of pouring to achieve the aggregate exposure desired. Course aggregate comes in three sizes: small, medium and large.

After achieving the type of aggregate exposure, the concrete is polished to a desired clarity of reflection. 1) ground to a flat shine, 2) honed to refined even appearance, 3) semi-polished, for crisp, smooth look or 4) highly polished, for a mirror effect.

3 Popular Concrete Densifiers Demystified

Concrete densifiers are also known as chemical hardeners. When applied to a concrete floor, a densifier fills empty spaces in the material and oftentimes forms a chemical bond with the concrete, changing its properties and increasing surface density.

Benefits of Using Densifiers

Densifiers are used specifically to improve the concrete surface when polishing. As long as free lime is present, the complete saturation of a densifier will make substrate harder, which allows a more aesthetically pleasing finish grinding and polishing, and prolongs the durability of the polish. Other benefits include:

  • Reduced dusting
  • Higher, deeper gloss than untreated concrete
  • Increased abrasion resistance and weathering
  • Longer floor lifespan
  • Locks in a topical color application
  • Stain resistance
  • Easier to clean

Types of Densifiers

Different types of densifiers create a chemical bond with concrete in a variety of ways. Runyon Surface Prep carries a wide selection of densifiers; below is a comparison of the three most popular.

Ameripolish – 3D Hybrid Silicate Densifier

  • Developed to help keep concrete looking newer longer
  • Improves performance of new, old or aged and existing concrete
  • Can be used with integrally-colored cements
  • Contains UV stabilizers to help protect color from fading
  • Penetrates fast for a deep seal
  • Hardens deep to improve durability even after grinding

Convergent Pentra-Sil Densifier

  • Developed to increase the integrity and life of concrete floors
  • Patented nano lithium hardener technology reacts with the concrete to produce calcium silicate hydrate (CSH), creating a strong, virtually impenetrable and durable finish with only one-coat and no rinsing
  • Resistant to bacteria

Prosoco Consolideck LS

  • Developed to improve the appearance and performance of architectural masonry
  • Gives new life to historic buildings, monuments, existing buildings, new masonry and reinforced concrete structures
  • Lithium silicate treatment reacts with the concrete to produce CSH
  • Safer, faster and easier to apply than conventional sodium or potassium silicate hardeners
  • Will not trigger or contribute to surface ASR (Alkali Silicate Reaction)
  • Resists damage from water

Get in Touch

If you have any questions about these three concrete densifiers, or if you’d like to purchase please visit our website or call us at 800.896.8665. We look forward to hearing from you!