Check out another successful polishing job by Exposed Design Group at a local taco shop. The acrylic surface was dirty and grimy before, so the Exposed crew went in and revived its sheen and color. This was an overnight job that was quick and efficient.
Torchy’s Taco Shop
Contractor: Exposed Design Group
Scope of Work: Exposed was approached by Torchy’s about a slip hazard on their floor. When the Exposed crew went and looked at it, it was an old stain/acrylic sealer job. Exposed then proceeded to work on grinding all of the material and grime off of the floor after business hours. After grinding, they gave Torchy’s a high-end polish, achieving a gloss factor between 75 and 85 throughout the entire store – even on the edges.
Result: You can see from the above left picture that this job was a huge success. All the stains were remedied with uniform color and the light reflected in the floor is so evident thanks to a quality polish.
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.
Before: all the prep work done
Concrete Hippo Mixing
Pouring Out the Concrete Overlay
Rolling Out the Concrete Overlay
Zinc Register Cut-Out
Finished Entry Way
Finished Living Space
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.
- 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
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!
Arguably, the core foundation and integral measure of quality for any concrete slab is determined by the overlay. Without a properly mixed, poured and spread concrete overlay, every other step in the concrete polishing process may suffer. ModernCrete is intimately aware of this fact, which is why their crew is so adamant about laying concrete floors that are well-prepared and executed. It’s safe to say they excel at it, with an average overlay installation rate at 250,000-400,000 square feet per year. ModernCrete’s attention and devotion to quality flooring inevitably results in beautiful, finished surfaces, as captured in the images below.
The finished look
Preparing the concrete overlay
Mixing the RapidSet TRU self-leveling overlay in HIPPO mixers
Letting the overlay dry
Spreading the concrete overlay
Pouring the TRU concrete overlay
The photos above were actually taken from 3 different projects, but they aptly display the steps of a typical concrete overlay application. The photos with hippo mixers were taken at a 5,000 square foot overlay in Houston, TX. On this job site the ModernCrete crew used 450 bags of Ardex PCT and AmeriPolish integral color. They then used HTC grinders with the Fenix system to polish the floor to a 3000 grit polish.
ModernCrete has perfected its concrete overlay process, with standard methods and products used on any concrete flooring application. They are outlined as follows:
- Hippo mixers are crucial for projects that call for a self-leveling floor installation
- Self-leveling compounds include: CTS RapidSet, Mapei, Ardex and Ultraflor PC-5614
- Hippo mixers allow you to mix up to 5 bags at a time, drastically reducing the amount of time and worker fatigue, as compared to traditional hand mixing
- AmeriPolish integral OS color adds color for clients who want it
- The Fenix polishing system from HTC is used to diamond polish most overlays
- During installation, steel porcupine rollers from CTS RapidSet are used to level the floor and release air entrapped by surface tension at the skin of the overlay
- Spiked shoes from Shoe-In Pro Finish make getting on and off spikes simple
- For floors that need to be taken down more than 1/4″ in order to prep overlays, a concrete shaver is ideal
More About ModernCrete
ModernCrete Concrete Design is a full service decorative concrete firm. It is headquarted in Austin, Texas – an environment perfect for the energy and artisanship operations vital to decorative concrete. Making concrete floors beautiful has been ModernCrete’s passion since 2001. It uses state of the art techniques and tools for superior results. Pride of workmanship is a hallmark of this company and its employees. And above all else, customer focused quality is integral. ModernCrete is committed to understanding your needs and making your concrete vision come to life.
For more information about how to properly apply a concrete overlay, the prep work involved, which products to use, etc. please contact us or write us in the comment section below. And to see more “real life” projects, visit our customer highlights category.
Creating 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.
- 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.
After last week’s training class with HTC Floor Systems, it only seemed fitting to create an infographic that outlines how to aptly use an HTC floor grinder and diamond tooling in conjunction with CTS RapidSet’s TRU self-leveling overlay. The below image aims to put this process in an easily understood form, one that flows and encompasses every element of the process. It is important to note why an overlay is preferred over simply polishing (in some instances) and how this effects which tooling is used, which grinder would work best, etc.
This visual guide provides a clearer explanation of how CTS RapidSet’s TRU and HTC’s grinders and tooling work well to grind and polish a concrete floor. However, please contact us with further questions or visit our website if you’re interested in purchasing any of the featured products.
With the Husqvarna training class starting tomorrow, it seemed fitting to create something representative of what the attendees may want to know more about. This infographic aims to do just that – explain the process of using Husqvarna diamond tooling when grinding and polishing CTS RapidSet TRU. On its own, these steps are fairly robust, but the following visual representation breaks it down into digestible sections. Please use this as a guide for your Husqvarna grinding and polishing applications, and if you have more questions after glancing over it, feel free to contact an expert for more info. And as always, leave us a comment or question below if you like!
Kneeling and bending are constant movements typical of working with flooring, and concrete especially. Getting up and down so much really takes a toll on your body and eliminates efficiency. So why not consider a tool to help make your work easier and less physically exhausting? The RACATAC cart roller with chest support allows you to do just that – free up both hands! As you use the RACATAC, you will find that by being supported in a kneeling position, and only having to swivel your knees to move, you eliminate wear and tear.
Model 01RAC3CS is 1″ higher off of the floor and allows your easier and quicker movement when you are in a kneeling or sitting position. This model is ideal if you need to move rather quickly in a lateral position, using it mostly on rough surfaces, or if you have large feet or long legs, or work mostly kneeling and sitting. Both the seat and chest support different angles, different heights, and slide on a rail front to back. This allows you to use both hands in different working positions while your back and knees are fully supported, and you can control your movement with your feet and toes. The support is made of comfortable dual density foam which connects and disconnects quickly.
Key Features of the RACATAC:
- Adjustable seat – provides upper body support
- Knee-pads allow your knees to rest and move freely
- 3″ casters – roll and move instead of crawling or bouncing
- Tool tray provides a place to keep necessities while rolling
Now you may wonder which applications the RACATAC can specifically be used for, and the answer is far-reaching. This cart roller is ideal for detailing, grinding, tiling, restoration, painting and autobody. Not to mention, this is such a new product and the first of its kind, which is why the appeal is so great. Why allow your job to be more difficult than it needs to be? Consider purchasing your first RACATAC – you can see the product page here. And, until Sept. 30th you can enter for a chance to win a FREE RACATAC! If this prospect makes you really excited, enter here.