Successful H.I.S. Concrete Polishing Job by Kent Companies

Kent Companies out of Michigan just completed a polish job at an H.I.S. facility. To prep the surface, the first step was removing mastic from the floor. The Kent crew used HTC metal bond diamonds to do this. Then they used Metzger/McGuire Rapid Refloor and L&M Durafloor TGA for patching and repair work. During this construction process, Duracover protected the substrate. The crew ran Ermator vacuums and HTC tooling under HTC grinders.

 

About Kent Companies

Kent Companies, Inc. is a full-service concrete construction firm with 55 years of experience in all aspects of commercial concrete applications.  As a 3rd generation family-owned business, they are deeply invested in the communities in which they operate.

Guide to Basic Floor Repairs with Metzger/McGuire Products

Metzger/McGuire makes industrial concrete floor repair and maintenance products that have set the standard in the industry for over 40 years.

Timely concrete floor repairs are essential to maintaining the seamless production schedules required in industrial and commercial businesses. Even a small crack or surface defect can create a hazardous situation, especially in locations where forklifts or other transport vehicles frequently operate. Metzger/McGuire is dedicated to protecting your clients’ concrete floors, and in turn their most valued assets, with products that will repair cracks, spalls, gouges, missed saw cuts, joint deterioration and pop-outs.

Guide to Basic Floor Repairs

We carry a full line of Metzger/McGuire Rapid Refloor and Spal-Pro floor joint materials, as well as Armor-Hard and MM 80. These polymer fillers are designed for use on industrial or retail concrete floors to repair cracks, surface spalls and pop-outs, as well as other defects that happen over time on concrete surfaces. This basic guide to floor repairs is a comprehensive checklist of general floor defects coupled with the proper Metzger/McGuire solutions and the tools required to get the job done right. Take a look:

Metzger McGuire Guide to Basic Floor Repair Poster

4 Critical Steps for Permanent, Durable Floor Repairs

In addition, Metzger/McGuire offers this advice for floor contractors:

  1. Determine the Causes of Floor Deterioration – Identify the underlying causes of floor defects before you begin repairing them, to determine the best long-term repair strategy. For example, if joint spalling is the result of an improper joint filler installation such as low filler profile or poor joint cleaning prior to filling, the wrong joint filler (urethane that is too soft to support traffic, or no joint filler at all), it’s an issue with the material. Joint spalling could also result from differing slab elevations, called slab curl or rocking slab conditions, which are structural problems that need to be corrected prior to performing standard joint repair.
  1. Select Appropriate Floor Repair Materials – Choose the repair materials best suited to meet the requirements of your facility’s operations. Considerations may include frequency of traffic, vehicle loading and types, building temperature, time allowed to perform repairs, defect width, etc. For example, the repair material best suited for a spalled joint may be heavy-duty, semi-rigid epoxy or polyurea, or a structural epoxy mortar. This depends upon:

a) the width of the spalled joint with wider exposures, requiring more rigid products

b) the cure time required

c) the current structural condition of the floor

d) the location of the defect, such as a freezer/cooler (polyurea is likely best, in this scenario)

  1. Prepare Defect for Repair Material – Failure to properly clean and prepare a floor defect is the number one cause of unsuccessful floor repair projects. The key to achieving long-lasting repairs is making sure the edges of the defect are defined and the defect is cleaned properly prior to filling with repair material. Even the best possible repair material will not function properly if it’s placed into a poorly cleaned joint or crack, or if the repair material is “feather-edged” along the outside of the defect. The edges of joints, cracks, and surface spalls all should be at least 1/2” deep vertically, and clean and dry prior to filling, to ensure the long-term durability and structural stability of any repair.

Finished Repair Should Be Flush with Floor – Simply filling a defect “even” with material generally results in a finished profile that is concave or dished, as repair materials typically settle a bit during cure. The goal in any floor defect repair is to restore a smooth, continuous transition across the floor surface. To achieve a flush profile, repair materials should be placed slightly higher than the floor and be allowed to cure, then shaved or ground flush with the surface. The finished profile of any repair should be “flush” with the floor’s surface.

Repair Your Spalls to Achieve a Durable Concrete Fix

Repair Your Concrete SpallsIn addition to concrete floor joint repair measures, every day wear and tear on a concrete floor can cause the surface to chip and crumble. This effectively means your concrete surface breaks into small pieces that create pock marks, nooks and crannies, deterioration, etc. However, surface spalling can be repaired using these steps.

Tools & Equipment

Repair Materials

Step 1. Make cuts with blade or chip out section at outer edges of spalling with a chisel to at least ¾-inch deep, creating a vertical edge.

Step 2. Grind out or chisel any spots of the floor with the work area that are higher than the level of the edges. Vacuum, brush and wipe the area clean with a rag.

Step 3. Overfill the area with repair material and trowel smooth and slightly higher than the floor surface.

Step 4. Once repair material is cured, remove any overfill to create a smooth, flush surface by grinding with a high quality polishing pad.

Runyon Surface Prep carries a full line of Metzger/McGuire repair materials designed for use on industrial or retail concrete floors to repair cracks, surface spalls and pop-outs, as well as other defects that happen over time on concrete surfaces. Find Metzger products on our website and videos of them in action on our YouTube channel. Please be sure to reach out with questions via the comment section below or by contacting us.

*photo courtesy of Metzger/McGuire

How to Fill and Repair a Concrete Joint in 2 Simple Steps

How to Repair Your Concrete JointsYou are tasked with fixing a deteriorated floor surface. Before your begin the repair, it’s important to determine the cause of the defects, which will help you find the best long-term repair strategy for the project. Any structural causes will need to be corrected prior to filling a joint.

Joints can be filled three different ways, depending upon the extent of the floor’s deterioration. If the existing filler is well-bonded structurally to one or both sides of the joint, you can refill voids without removing it entirely, or making a partial removal. However, if the existing filler is not well-bonded or appears to be installed improperly, remove it completely before making the joint repair.

Three Considerations

Consideration 1: Select floor repair materials that meet the requirements of a facility’s operations. Consider frequency and type of traffic — foot, vehicle, heavy equipment. Also consider building temperature, the surface area to be repaired and the work window you have to complete the repair. This will help determine whether you need to use more rigid products for large repairs, if epoxy products will have the time required to cure or if you’re working in a freezer or cooler room.

Consideration 2: Prepare the surface for long-lasting repair by making sure the area is well-defined and cleaned properly prior to filling with repair material. Proper surface preparation is critical to a successful repair. Take care that the edges of joints, cracks and surface spalls are at least 1/2-inch deep and the area is not only clean, but dry prior to filling.

Consideration 3: Avoid a concave or dished joint by filling with repair materials slightly higher than the floor surface. Once cured, the excess material is ground or shaved to meet the original surface, restoring a smooth, continuous, flush profile across the floor.

Tools & Equipment

Repair Materials

The Process

Step 1. Use joint cleaning saw or right angle grinder equipped with a braided wire wheel or suitable diamond blade to remove existing joint filler to a nominal depth of ½-inch below surface, making sure all filler residue is removed from joint walls back to clean concrete. Vacuum joint clean.

Step 2. Overfill joint with appropriate filler. Allow filler to cure, then razor flush with floor surface.

Additional Resources

In addition to these tips, products and processes, please take a look at our YouTube page for specific joint repair videos taken during various training classes (presented by experts from Metzger/McGuire). Also, please comment below or contact us with additional questions, or visit our website for a full listing of Metzger/McGuire products.

Exposed Floor Design Rebuilds and Refills Sysco’s Joints with Ease

In a previously featured story, Exposed Floor Design Group filled the joints in a new Sam’s Club store, and it turned out really well. The same can be said for the concrete floors located throughout a Sysco Food Distribution center, as per the image below. Joint filling and joint repair are areas of expertise for Exposed – they pride themselves on giving floors new life.

Sysco polish job - Exposed

Project: Sysco Food Distribution in Lewisville, TX

Scope:  Joint Rebuild/Refill

Materials:  ArmorHard Extreme and RS88

This project entailed repairing joints throughout a heavy-use distribution facility. Obviously a food distribution facility has to maintain significant levels of cleanliness and sanitation, all the while, they must maintain production. The Exposed crew could not close them down, so they chose products that would get them back to service before the next morning. The choice was easy for these joint rebuilds: ArmorHard Extreme was the only way to go.

Keys to Success:

  • Preparation is key! Use the right tools to “square up” the spalled edges of the joints.  Remove any contamination in the joint area before you prime the surfaces.  A good bond is vital to the joint surviving.
  • Mix it right! The Exposed crew likes to mix the liquids, then add in aggregate to get the right consistency.  This project worked best at a “mortar-like” consistency.  Make sure the mixture is lump free.
  • Don’t overwork the material! This is where skill and experience comes to play. Get the material in, compacted and smooth, then leave it alone.
  • Recut the joint! It is vital to recut the joint to allow movement in the slab when rebuilding joints. The key here is to make sure you cut all the way through the ArmorHard, so it is not bonded at the bottom of the joint.
  • Refill the joint with RS88 “full depth.” Don’t cheat here! The RS88 in the joint will bridge the joint as traffic passes, and it will minimize stress to the new ArmorHard egdes. If you do not go full depth, you risk stressing the bottom of the joint repair and it may fail.
  • The ability to prep, prime, rebuild and return to service was a requirement of this job, and ArmorHard Extreme allowed Exposed to succeed!

For more details on the products used, the process of refilling or repair a joint, etc. please contact us. And be sure to check out our other WOC featured stories!

A Successful Sam’s Club Joint Fill Job by Exposed Design Group

Sam’s Clubs endure a large amount of wear and tear, not surprising considering their high volume of traffic. So in addition to regularly maintaining these floors with cleaners, scrubbers, etc., it is also prudent that spalls, cracks and joints are periodically repaired. Exposed Design Group prides itself on the ability to restore concrete floors in this very manner, as evidenced in the photo below.

Sam's Club Polished Store - Exposed

The Project:  a new Sam’s Club store in Burleson, TX

Main Materials Used:  Metzger/McGuire MM-80 and RS88

A little bit of commentary

In a high-traffic load setting like a Sam’s Club, MM-80 was the joint filler of choice for repairing the joints throughout the club’s sales area.  The benefit of using MM-80 over other products is its ability to carry heavy loads on forklifts across floor joints. On the other hand, in the deli/food prep areas, Sam’s decided to use integrally colored concrete and RS88 polyurea.  The benefits here include color choice and speed — how little time it took for the material to cure. As an installer, Exposed preferred the standard MM-80, as its crews could more easily fly through the store, shooting thousands of feet a day by hand. Then the next morning they shaved it off.

More About Exposed:

Exposed Floor Design Group, LLP was formed to bring highly specialized skills to the residential and commercial finish-out community. With more than 25 years of experience in general contracting, waterproofing, decorative concrete and polished concrete, the partners of Exposed Floors have the combined background and diversity to provide customers a service that cannot be matched. Exposed Floors has invested in the right equipment and training of its craftsmen. Each of their products and services require specific, skilled processes, as well as impromptu solutions, to give customers the floors they desire.

If you have more questions about the above project, the Metzger/McGuire products used, etc., then please contact us. For more customer highlights, visit our featured section, and be on the lookout for more to be added soon.

Exposed Floor Design Repairs and Renews Brookshire’s Concrete Floors

How do you change out the floor in a grocery store that remains open for business? The easy answer: use the right tools for the job. Exposed Floor Design Group had to work the night shift at a Brookshire’s store in Texas from 11pm to 6am, which did not provide a lot of time to get work done, especially when allowing for curing. However, the crew managed well by following tried and true steps and by using highly trusted Metzger/McGuire products. You can see how well the store’s floors turned out in the gallery below.


Project: Brookshire’s Store in Kaufman, TX

Scope: Remove VCT, Repair Slab, Grind, Polish

Materials:  RS88, Rapid Refloor, ArmorHard, Pentra-Sil

The Process:

  1. First night: demo VCT and remove glue with first grind
  2. Second night: repair holes with Repid Refloor (color matched to the slab, “High Tea”) and polish up to 800’s
  3. Third night: move the racks between the areas completed night 1 and 2, demo, repair, polish and reset racks
  4. Fourth night: polish the whole floor throughout

The Stunning Results:

The customer was incredibly impressed by the Rapid Refloor product. They found it to be aesthetically better, as it can be color matched, in addition to being durable and smooth. The key to Rapid Refloor repairs is to remove dirt from spalls, square the edges and sand flush to the floor. Exposed uses Rapid Refloor in the same way for several of its customers.  When you have small dents, chips and dings on your floor, Rapid Refloor is a great solution!

For questions about this project, the process or the products, feel free to contact us or write in the comment section below! Also, be sure to find many more customer feature stories on our blog here.