Case Study: A Successful TRU Overlay Job in Sioux Falls, SD

Dan Knuth, our technician and training specialist, assisted on a TRU job a few weeks ago in South Dakota for Custom Concrete Creations. There were some issues with material flow and color application, so he helped troubleshoot and in the end assisted in producing a successful overlay. Read on for the details of what they did and how they combatted various problems.

 

The floor layout was too wide to complete in one pour, so it was divided into three 10′ wide areas. The three areas were sectioned off with weatherstripping. We did this to maintain a 3/8″ depth throughout the entire floor. The wider the area is, the more difficult it becomes to get a consistent depth of at least 3/8″ because the material wants to flow as more material is placed in front of it.

The first 5 bag batch of TRU was mixed for 2.5 minutes and was too fluid. This was apparent when the mixing material was poured through an 1/8″ classifier screen to catch any unmixed material – it went through the screen like water. Fortunately, the floor had a trench that was 1-1/2″ in depth, so we just poured the material in the trench as an “underlayment.” We took 16 oz of water out of the next mix, mixed for 2.5 minutes and it was still too “watery” so we poured the second batch in the trench as well. We took another 16 oz (32 oz total) out of the third mix, mixed for 2.5 minutes and it resulted in the desired flow we were looking for, so at that point we began pouring the floor.

The next day the first order of business was to cut and fill the control joints. Control joints in the substrate were fairly straight, so we marked them on the wall prior to pouring so they could be recut. This was the first order of business because we were only going to use one metal-bond diamond and it is recommended to fill control joints right before your last metal-bond. We then began cutting the floor with medium soft 80 grit metal-bonds underneath an HTC 800 Classic and an HTC 800RX.

After the first cut, the skin was removed on 95% of the floor and we had good sand exposure. However, a second cut was completed with the same diamond to achieve more consistent skin removal and sand exposure. 100 grit HTC Fenix pads were then used to remove the 80 grit scratch and worked well on the three head 800 Classic, but the four head 800RX had to switch from the Fenix pads to the 100 grit HTC Big Blocks to remove the 80 grit metal-bond scratch before using the 100 grit Fenix pads. 200 grit Fenix pads were used, the floor was scrubbed, then Ameripolish’s 3DHS densifier was applied. Husqvarna’s Overlay Flex Polishing Pads were used to polish the floor (400 grit – 3000 grit) after densification was completed. Finally, a guard was applied and burnished to complete the project.

Custom Concrete Creations specializes in polished concrete flooring. They service industrial, commercial and residential clients throughout the Midwest. Other services include acid staining, sealing, joint filling and floor prep.

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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.

Successful Industrial Freezer Repair Project by Exposed Design

Repairing concrete in industrial-sized freezers is always a challenge. However, Exposed Design Group tackled such a feat with a little ingenuity, high-quality products and much-needed industry experience. This freezer project demonstrates the importance of concrete flooring maintenance in high traffic [forklift] areas, not to mention why using the correct chemically-formulated repair products is vital for such a volatile part of any industrial facility.

Project: AMC Freezer

Scope: Resurface deteriorated concrete in -10degree freezer

AMC was not happy with the surface of its freezer floor as it was old and deteriorating. The facility was experiencing excessive monthly forklift repair costs and had several 55 gallon drums full of damaged forklift wheels. The Operations Manager inquired about which options he had for achieving a smoother slab surface. After researching several potential options, Exposed decided that a skim coat of a polymer rapid repair product rated to negative 30 degrees would be the best solution.

Process:

  1. Repair cracks (before/after)
  2. Grind/clean surface (before/after)
  3. Apply skim coat – (during/after)

The process included repairing all cracks and surface defects with a fast-curing polymer repair product, followed by a light grind to open up the surface of the slab. The final stage of the rehab included squeegeeing a skim coat of the same polymer rapid product to provide a more durable and smoother floor finish for the customer.

Results:

The floor was repaired 8 months ago, and the customer couldn’t be happier with its performance. As a result, this successful rehab project reduced their material handling device repair costs and has increased their operational efficiency.

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!

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!

Hunter Advanced Concrete Polishing: Christensen Field Floor Makeover

There is something to be said about a concrete floor that is enlivened and totally transformed with a natural grinding and polishing process. It is obvious after little time when a floor is done poorly, but properly polished concrete that is maintained will exhibit a long-lasting sheen. Hunter Advanced Concrete Polishing embodies this concept and is to be admired for the highlighted project below.

For years, Hunter Advanced Concrete Polishing has been a preferred provider of some of the region’s leading retailers, restaurateurs, contractors, schools, municipalities, commercial and industrial, and others who understand the value of their property – and the importance of preserving it. What began as a small family business has become an enterprise with more than 20 employees. Together they continue to apply the very best techniques and learn-by-doing to ensure that every job is done right. From the materials used, to the equipment and techniques used to apply them, Hunter ensures high quality craftsmanship in the production of polished concrete floors that instantly become a mark of pride for their customers.

Project Overview

Hunter ACP was tasked with transforming the above main arena floor at Christensen Field in Fremont, NE. It was in fairly rough shape before, as evidenced in the top left picture, due to a poorly executed resurfacing job by a different contractor two years prior to Hunter getting their hands on it. The Hunter ACP crew first ground down the surface with a Husqvarna grinder and rugged diamond tooling. Then the crew filled in the 2″ wide joints with joint filler from Metzger/McGuire. And the final step in the process was polishing the entire surface to the desired shine by working up to a higher grit with each pass.

Products Used

The Lasting Results

Hunter ACP is a large proponent of a natural, long-lasting result achieved from truly polishing a surface, not simply applying a protectant and then burnishing, which will wear and dull more quickly over time. Thus, the truly polished floors at Christensen Field should last for years to come, especially when maintained to Hunter ACP’s prescribed specifications. Hunter ACP guarantees that the floor will not spall or lose its luster as long as the maintenance program is followed, which is something to consider. A maintenance program is vital for the upkeep and lasting effect of a concrete surface, especially when heavy foot traffic is a factor.