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!

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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!

M&C Concrete’s Wide Array of Contracting Opportunities and Specialities

Concrete creates an incredibly durable surface, and rightfully so considering how common it is in many industrial and commercial environments. Look around any mall, government building, doctor’s office, or really any business and you’re likely to find concrete floors. Due to its incredible wearability and resistance to stains, foot traffic, etc. (when maintained properly that is), it’s no wonder that polished concrete is quickly taking the place of carpeting, tile or hardwood in commercial floor settings. M&C Concrete is a local Indianapolis contracting company that realizes this fact, which accounts for its wide array of clients, as evidenced below.

Brief Overview

1. Local car dealership: M&C laid the concrete, ground and polished

2. Fire station: CTS RapidSet TRU self-leveling overlay with integral color and AmeriPolish dye used for the logo

3. World of Concrete 2013: M&C helped us lay the concrete slab, grind, polish, etc.

M&C At A Glance

M&C Concrete is a leading concrete contractor in the greater Indianapolis market. Established in 1982, it has successfully completed over 10,000 projects in both residential and commercial sites. As a leader in the industry, M&C strives for customer satisfaction, on-time project completion and being at the forefront of the latest concrete design and construction.

For more information about M&C, the products, the process, etc. please feel free to contact us or leave a comment below. Also, be sure to check out our other customer features!

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.

Truly Elegant Decorative Concrete Designs Liven Up A Space

The decorative concrete industry is constantly innovating and pushing out new, creative designs, for both residential and commercial flooring. A colorful, patterned concrete surface not only creates a lasting impression, but it can set the tone in a space. This is the case for a recent job completed by Elegant Concrete Polishing in an elementary school in Connecticut. The bright colors and swirling shapes and curves evoke an energetic vibe throughout, as you can see in the images below.


Connecticut Elementary School Project

The pictures above are of the 17,000 square foot elementary school. The Elegant Concrete crew installed the polished concrete flooring using the AmeriPolish SureLock System. The slab was ground and polished from a 40 grit metal all the way up to a 1500 grit resin. The decorative flooring design was installed per the architectural layout, established with another firm that Elegant has built a solid relationship with. In order to accomplish such a colorful finished product, Elegant used 6 different colors from AmeriPolish in the initial overlay stage. Colors include: Patriot Blue, Turquoise, Forest Green, Green, Burnt Sienna and Sepia. After polishing the floors completely, Elegant protected them with SureLock Densifier and sealed them with SureLock Stain Shield.

Elementary School Concrete EdgesUsing Terrazzo to Create a Border

In another project Elegant completed recently, the crew installed CTS RapidSet TRU self-leveling overlay and then used a zinc terrazzo bar around the perimeter to act as a divider for the border. Elegant ground and polished the TRU after it was entirely laid and set. Then finally, the crew dyed the perimeter band with AmeriPolish OS Dye in Terra Cotta to give it a two-tone effect and clearly establish the border from the main center area. In the picture to the right you can see how crisp and polished (so-to-say) the terrazzo strips are in conjunction with the polished concrete. Although a slightly more expensive material to use on a slab, the result is unparalleled.

Get to Know Elegant Concrete Polishing

Elegant Polishing, Inc. is located in New Haven, Connecticut, and area known for its sustainable flooring solutions. Over the years, floor finishing and restoration has evolved to a more durable and environmentally friendly solution. Every year, hundreds of products are introduced into the residential and commercial, industrial market. Elegant Polishing’s goal is to listen to your specific needs and come to the best solution for your project.

 

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 Prime Example of Preparing and Executing a Concrete Overlay

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.

 

Project Details

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.

Rules-of-Thumb

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.