Grinding Concrete (old)

Grinding & Leveling

Floor Grinding 3

 

 

 

 

 

 

Grinding concrete eliminates raised trip hazards in sidewalks and other walkways.
If you have a business, the Canadians with Disabilities Act might even require you to grind down raised trip hazards. Concrete grinding can save you hundreds or thousands of dollars over a complete surface replacement.
With the right grinding equipment, it’s possible to take on just about any job, from sanding a small hump in the cement to excavating a 1” trench hundreds of feet long.

Floor Grinding Cement floors are never completely smooth and level. Cement slabs always have hard-to-see imperfections. A smooth, level surface is critical before installing tile, linoleum or engineered laminate flooring.
Professional concrete grinding contractors can make your floor level enough for any purpose, whether it’s tile or linoleum installation or polishing and staining the floor to a high sheen.
Here’s how the process works: Any high spot 1/8” or higher will require grinding to level the floor. The contractor will systematically check the floor in every direction to identify these high spots.
Then the proper type of grinder will be chosen, whether it’s a hand-held models or a larger machines that resembles a floor buffer.
Grinders use diamond tipped or diamond embedded wheels or pads to remove excess cement. A professional will know exactly how much to grind. Beware: Inexperienced amateurs will often over-grind and ruin your cement floor.

Here are some possible cement floor problems that might require grinding or sanding:
A slab reinforcing bar too near the surface causes the cement to crack.
Ridges or humps left by the finishers.
Expansion or contraction cracks.
Debris like chunks of wood floating out of the slab while it is still plastic (wet).
Damaged caused by heavy objects being dropped on the slab before it has cured.
Diamond grinding is a concrete pavement restoration (CPR) technique that can repair cracks in cement floors. When compared to overlay or patching methods, diamond grinding can cost less and last up to 3 times longer, while providing a greener solution.
Diamond grinding removes faulting, slab warping, studded tire wear and unevenness resulting from patches in roads. Diamond grinding also lowers road noise by providing a longitudinal texture, which is quieter than transverse textures.
Conclusion
Grinding Concrete is the best solution for dealing with uneven concrete surfaces, such as grout build up, humps in the floor and uneven pours. Floor grinding can be used indoors (with dust control equipment) and outdoors. The alternative is often removal and replacement, which is much more costly.
Grinding concrete floors to achieve a highly polished surface is also becoming more and more popular, from businesses to residential homes. These floors can be a more economical, practical and decorative flooring choice for any facility.
Due to the complexity of the work and the tools used, floor grinding is a job best left to professional contractors. Prices can vary depending on the scope of the job and the amount of cement to be removed. Always hire a professional floor grinding contractor who will protect your investment in your home or business.

Floor Leveling
These have a 4 to 6 inch disc and the speed is the fastest you need to use for safety reasons. Most common discs for this grinder are masonry discs; these are of composite material such as carbide, granite with fiberglass binding. These wear semi fast. This is the most versatile of the group, you can grind all masonry surfaces and it’s very soft if you add no pressure or if you push on in it becomes more aggressive. You’re able to get into tighter areas to grind plus it can be used flat or held at an angle. This grinder can be fit for a diamond wheel as well. Cutting wheels are very thin and can only be used on the edge not in the flat position. This grinder spins very fast. The next wheel that can go on this is the planer; this wheel is made of the same material as the cutting wheel, diamonds. This wheel is made to use in the flat position only. This is the most aggressive tool. For a journeyman concrete finisher this is a tool that can be perfected and can do beautiful work out of ugly concrete. This is the machine and wheel you would use on a floor if you had a crack and it began to lift apart till one side was higher, the diamond wheel would make short work out of it and level so you could never tell the slab rose up.

Concrete Polishing

Concrete Polishing (2)

What Is Polish Concrete ?

 Our business is polished concrete floors, acid staining floors, and dyed concrete. Our polished concrete floors, acid stained floors and dyed concrete floors are found throughout the Mid Atlantic area in government facilities, schools, retail and commercial applications. We provide concrete polishing services to architects, business owners, general contractors and project management companies. We see your polished concrete flooring project through until the end; from the specification process to maintenance of your project. We offer a turnkey polished concrete process. We use the ULTRAFLOR ARDEX DIAMATIC Polished Concrete System. The ULTRAFLOR System is the only comprehensive polished concrete system with a detailed written process specifications for all aspects of the installation. We can ensure you a successful installation of your polished concrete floors, acid stained concrete floors and dyed concrete floors done on time and on budget.

For more information on our concrete acid staining or
polished concrete systems, call us 416 274 3418

We use environmentally friendly concrete polishing systems. These green concrete products and sustainable processes have a proven success record. In addition, we offer our clients an extended warranty on both our product and labor. We use the most advanced equipment and constantly update our concrete polishing methods to stay on the cutting edge of this rapidly changing technology. Be sure to utilize our unsurpassed expert advice for your polished concrete floors, dyed concrete floors and acid staining floors.

For Terrazzo floors we use gentle, professional polishing to bring the life and shine back every now and then. Terrazzo flooring is a work of art in itself. Did you know Terrazzo originated in Italy as a mishap creation? Italian mosaic artisans would cast aside the remnant marble chips from their projects onto terraces in the process of being built. Over time people stepping back and forth over the terrace floors would cause the littered marble chips to be pushed further down. Shuffling feet would cause the floors to be smoothed to a polish. This idea has been refined over the centuries and it is still a widely used concept today. Terrazzo polishing will prolong the life of your work of art.

For your commercial or residential concrete contractor needs, we can repair or demo your concrete and clean up the mess. For an affordable and knowledgeable solution to your flooring issues feel free to contact us. From floor prepping, leveling and grinding to concrete work and Terrazzo polishing we can do it all give Concrete Repairman a call.

Polished concrete floors are easy to install and maintain, offer increased strength and durability, and will decrease your floor maintenance and cleaning costs. Acid staining concrete floors or updating your industrial flooring with dyed concrete can make your facility more attractive, yet more cost effective at the same time. Contact us today to see how.

Do you have Terrazzo floors? If you do you know they need gentle, professional polishing to bring the life and shine back every now and then. Terrazzo flooring is a work of art in itself. Did you know Terrazzo originated in Italy as a mishap creation? Italian mosaic artisans would cast aside the remnant marble chips from their projects onto terraces in the process of being built. Over time people stepping back and forth over the terrace floors would cause the littered marble chips to be pushed further down. Shuffling feet would cause the floors to be smoothed to a polish. This idea has been refined over the centuries and it is still a widely used concept today. Terrazzo polishing will prolong the life of your work of art.

For your commercial or residential concrete contractor needs, we can repair or demo your concrete and clean up the mess. For an affordable and knowledgeable solution to your flooring issues feel free to contact us. From floor prepping, leveling and grinding to concrete work and Terrazzo polishing we can do it all give Concrete Repairman a call.

 The successful completion of a diamond polished floor is dependent on two important factors:

  • The quality of the concrete floor slab on which the diamond polishing will take place.
  • The quality of the applied products and polishing equipment combined with the skill and abilities of the polishing company.

CPAA offers guide specifications to design professionals and the construction industry that addresses the second of these two important factors, however, the diamond polishing company has no control over the design, specification, or placement of the concrete floor slabs that are to be polished.  To address the first of these two important factors, CPAA recommends the following design and construction recommendations be evaluated for inclusion in the Division 03 cast-in-place concrete specifications prepared by the project structural engineer. DIAMOND

POLISHED CONCRETE IS NOT TERRAZZO A diamond polished concrete floor is not like terrazzo:

  • Terrazzo is mixture of matrix and aggregates that are topically applied to a concrete floor then polished; diamond polishing is a process of finishing the concrete floor using grinding and polishing equipment along with concrete chemicals.
  • Application of terrazzo and diamond polishing covers the concrete floor that was placed months earlier and followed by the construction of a building over it, however the terrazzo will cover the concrete floor but the diamond polishing finished the concrete floor that is there.
  • The cementitious or epoxy matrix color can be selected for terrazzo, however, the concrete floor slabs is a product of the local concrete producer and there is very little, if any, ability to influence the color.
  • Aggregates for terrazzo can be selected, however, the aggregates for diamond polished floors is the aggregate normally used by the concrete producer.

The point is that a diamond polished concrete floor cannot be thought of as a terrazzo floor. It is a different process that is not a covering and depends on heavily on the quality of the concrete. EARTH SUBGRADE CPAA recommends fine grading the subgrade uniformly flat using a laser device. Imperfections in the subgrade surface, such as rises and depressions, could cause variations in the thickness of the concrete which increases the possibility of cracking because of restricted movement.  A uniformly flat subgrade surface reduces the potential of cracking because the concrete slab can expand and contract with minimal friction.  While cracks can be filled during the polishing process, they cannot be made invisible by the polishing contractor. Also, depressions in the subgrade could allow bleed water to pool on top of the below slab vapor barrier during plastic state of concrete which could cause blemishes in the concrete surface because of the differential curing and drying.  Blemishes such as this cannot be eliminated by the polishing contractor. BELOW SLAB VAPOR BARRIER Moisture movement from earth subgrade through the concrete slab-on-grade to the concrete surface is a major problem in the flooring covering industry today, and can adversely affect a polished finish as well.  A high-performance vapor barrier between the subgrade and the concrete is extremely important, therefore CPAA recommends a membrane that is rated Class A according to ASTM E1745 – 09 Standard Specification for Water Vapor Retarders Used in Contact with Solid or Granular Fill under Concrete Slabs that has the following properties:

  • Permeance:  Not more than 0.1 perms (grains/sq ft/hr/in-Hg) after conditioning testing according to Section 7.1 of ASTM E154 – 08a Standard Test Methods for Water Vapor Retarders Used in Contact with Earth Under Concrete Slabs, on Walls, or as Ground Cover.
  • Thickness:  Not less than 15 mils.
  • Tensile Strength:  Not less than 45 lbf/in.
  • Puncture Resistance:  2200 grams.

Installation of the vapor barrier should comply with ASTM E1643 – 09 Standard Practice for Selection, Design, Installation, and Inspection of Water Vapor Retarders Used in Contact with Earth or Granular Fill Under Concrete Slabs. CONCRETE MIX DESIGN In addition to ACI standards for mixing concrete, CPAA recommends the following:

  • For the portion of the concrete that will be polished, each mix ingredient should be from the same source, from the same respective batch, and each delivered to the concrete producer in one delivery.
  • Type I portland cement according to ASTM C150 – 09 Standard Specification for Portland Cement.
  • A water-to-cement (W/C) ratio is .45.
  • One of the strengths of diamond polished concrete is the range of aggregates that can be exposed, therefore a uniformly graded mix of not less than 3 aggregate sizes – fine, intermediate, and large – will yield the best visual quality.  It should be understood that since aggregates are heavy and there is a cost for transporting aggregate from its source to the batch plant is a factor in the cost of the concrete, locally available aggregates are used to produce concrete.  This is an important design consideration because, depending on the project location, there may be few, if any, opportunities for other aggregates to be used in the concrete mix.
  • The mix should not be air entrained.
  • Inclusion of admixtures, plasticizers, slag, fly ash, or other products replacing portions of the portland cement in the concrete mix is not recommended.  If any of these are used, the total volume should not exceed 20 percent of the portland cement volume.
  • Admixtures should not be calcium chloride based.
  • If an integral color is included in the concrete mix, the minimum batch size should be 3 cubic yards.
  • During batching, the incoming material consistency should be monitored and controlled.
  • The compressive strength should not be less than 3,500 psi.

 

PLACING CONCRETE
In addition to ACI standards for placing concrete, CPAA recommends the following:

  • Transit mixer drums should be properly washed out after each concrete mix discharge and before a new batch is loaded.
  • Water added by the transit mixer driver should be monitored and controlled.
  • During mixing, transporting, and placing the concrete mix, monitor and control the temperature to not more than 85 degrees F.
  • The slump at the point of discharge should be 5 inches, plus or minus 1/2 inch.

 

FINISHING CONCRETE
In addition to ACI standards for finishing concrete, CPAA recommends the following:

  • After placement of the concrete mix, strike off the surface using a laser screed, then bull float at 90 degrees to the screed pull direction, vib and consolidate, and level to specified elevation.  A 10 foot check rod is recommended, however, if not available bull floats should be 6 foot long; smaller bull floats may be used on sloping surfaces.
  • When placing concrete mix at edges, use a 36 inch long metal or wood edged screed and run parallel with the formwork or edge after the initial screeding and before floating.  Hand floating should be parallel to the edge and performed in 24 inch increments to avoid lifting or depressing the surface.  Avoid pulling excessive amounts of the concrete mix to the edges by either not using hand tools more than 24 inches from the edge, or floating in a fan direction.
  • When little or no bleed water is present and concrete mix has sufficiently hardened to support finishing equipment without causing imperfections in the surface, begin machine floating using pans and make two passes.
  • To improve the possibility of achieving the specified flatness/levelness requirements, check and re-straighten if necessary using a 10 foot or longer highway straight edge or bump cutter.
  • When machine floating edges, use pans and overrun the formed edge by 5 inches.  For both walk-behind and riding equipment, make the first pass along the edge with the left side, or cutting side, of the equipment to pull down high spots of the surface.  Make a second pass along the edge with the right side, or filling side, of the equipment to fill low spots in the surface.
  • Steel trowel the surface in three passes without burning the surface or burning the aggregate (plastic trowel blades will prevent burning the aggregate).
  • Lightly hand or machine tool edges construction joints and exercise care that edges are not depressed or chattered along bulkheads, formed edges, columns, and pipe penetrations.
  • Do not dust the finished surface with dry portland cement or sand to accelerate curing and drying.

 

CONCRETE CURING AND DRYING

CPAA recommends evaporation control and wet curing concrete slabs according to ACI 308R-01:  Guide to Curing Concrete (Reapproved 2008) without the use of topically applied curing compounds.  While topically applied curing compounds may assist with curing during the first few days after concrete placement, they retard concrete drying in the weeks and months after curing and may cause the slab to be too wet when the time comes for diamond polishing or floor covering application. Densifiers and hardeners should not be applied to concrete. FLOOR FLATNESS/LEVELNESS CRITERIA CPAA recommends specifying the following tolerances:

Floor Flatness Specifications: ASTM International

The floor flatness and levelness should be tested within 8 hours after completion of the final troweling operation according to ASTM E1155 – 96(2008) Standard Test Method for Determining FF Floor Flatness and FL Floor Levelness Numbers by an independent testing agency experienced with the testing procedure and possessing the necessary equipment. Additionally, a remedy for out-of-tolerance work should be specified. CONTRACTION JOINTS Based on independent studies, CPAA recommends saw-cutting slabs as soon as possible after finishing using a saw blade that has a triangular arbor configuration to reduce edge raveling or dislodging aggregates at the following spacing to minimize slab curling and cracking:

Since concrete shrinks during curing and drying in two directions, cracks are minimized when the area between contraction joints is as close to a square as possible. PROTECTION CPAA recommends the concrete finishing specification include a requirement that the finished concrete slab comply with the damage and stain prevention provisions specified in the diamond polishing concrete floors specification.

 

Stained Concrete

Stain Concrete

Local licensed stained concrete flooring contractors for commercial residential projects decorative concrete floors ideas colors and textures.

Acid staining

Colors and Coloring

Acid stain is not a dyeing or pigment-base coloring systems, but a chemical reaction. A mixture of water, mineral salts and a slight amount of muratic acid is applied to the floor. This chemical reaction with the existing minerals (primarily lime) over a period of one to four hours creates new earth tone colors on the floor. The floor is later scrubbed to remove excess stain and neutralized by a basic solution of ammonia and water or baking soda (less likely to cause whiting later) to help raise the ph level back to normal level. Due to inconsistencies in the surface level of concrete floor, acid staining creates a variegated or mottled appearance that is unique to each stained slab. The color penetration ranges from 1/16 to 1/32 of an inch. Older exterior concrete surfaces may not color as well as interior surfaces because the environment has leached or percolated out the mineral content. As well, any exposed aggregate (rocks) in worn concrete will not accept staining.

Stained Concrete Floors

How to prep floor for

We grind our floors to open up the surface to except the colored salts of the stain. Our grinding method do not leave any markings in the floors that will show up later in the finished floor. After grinding and profiling the floor for staining, the floor is cleaned using water and vacuums. The stain is the applied liberally in a circular motion from a acid resistant pump sprayer. Depending upon the desired look, stain can be applied in just about any manor you can think of, being careful not to show brush strokes.

Industrial Coatings

Industrial Coatings

Mack Contracting industrial concrete coatings offers and wide range of specialized floor coatings with many performance options to meet specific job requirements. Coating systems based on epoxy and polyurethane chemistry provide permanent substrate adhesion, chemical and wear resistance along with easy soil release. Available in many attractive colors, these systems range from 6-20 mils in thickness. Light reflective high gloss finishes provide a clean, bright facility appearance that enhances your company’s image.

Urethane Modified Concrete

Castorcrete is designed for use in the most demanding food and beverage processing areas where high resistance to impact, abrasion and chemical resistance to organic food acids is required. Castorcrete is formulated with renewable raw materials and contains no VOC’s, making it a viable option for environmentally friendly projects. It offers exceptional thermal shock resistance and is available with an anti-microbial additive to inhibit the growth of bacteria and micro organisms.

Not only is Castorcrete durable and environmentally friendly, but it was also designed to address limited work time. This is a common industry problem that often occurs during the installation of polyurethane concretes. In response to this, Castorcrete has 2 formulations, fast cure formulation was designed for installations that require a quick turnaround. Regular cure formulation offers more work time and a slower set time which equates to a much easier installation and better overall aesthetics of your finished flooring system.

Urethane Mortor

The physical properties of urethane mortar systems are far superior to that of epoxy systems when it comes to specific applications such as heavy duty industrial food processing., pharmaceutical manufacturing facilities, breweries or meat, fish and dairy processing plants.Withstands heavy abuse, very low odor, no risk to open food products, impervious to radical temperature changes, withstands extreme temperatures.

Castorcrete TG

Castorcrete TG is a heavy dety trowel applied urethane mortar that is designed to resurface badly deteriorated concrete and withstand extreme physical and chemical abuse including steam cleaning, steel wheeled carts and heavy impact. Castorcrete TG has outstanding chemical resistance to most solvents and is perfect for areas exposed to strong acids, alkali, hot oils and animal fat.

Castorcrete RT

A heavy duty flow-able urethane mortar that is designed to resurface moderately deteriorated concrete and withstand extreme physical and chemical abuse, including, but not limited to steam cleaning, carts and heavy impact. Castorcrete RT produces a smooth, easy to clean matte finish. A heavy duty flow-able urethane mortar that is broadcast with colored quartz. The Castorcrete RT-B system is designed to resurface moderately deteriorated concrette and withstand extreme physical and chemical abuse, including, but not limited to steam cleaning, carts and heavy impact. Castrocrete RT-B produces a textured surface ideal for wet environments. The use of blended color quartz offers improved esthetics.

Castorcrete SL

Amedium-dudy urethane slurry that is designed to resurface concrete and withstand physical and chemical abuse, including, but not limited to high abrasion and impact. It also has outstanding chemical resistance. The Castorcrete SL system produces a smooth, easy to clean matte finish.

Castorcrete SL-B

A medium-duty urethane slurry that is broadcast with colored quartz. This system is designed to resurface concrete and withstand physical and chemical abuse, including, but not limited to high abrasion and impact. It also has outstanding chemical resistance. Castorcrete SL- produces a textured surface ideal for wet environments. The use of blended color quartz offers improved esthetics.

Castorcrete CM

A heavy duty urethane mortar that is designed for troweling cove. Castorcrete CM can withstand extreme physical and chemical abuse including steam cleaning and heavy impact. The outstanding chemical resistance of Castorcrete CM is well suited for areas exposed to strong acids, alkali, hot oils, animal fat and most solvents.

 

HD Epoxy

Epoxy

Epoxy Floors

Epoxy floor coatings for industrial floors, garage floors, driveways, patios and slabs of all size for commercial and residential projects in Arizona. Epoxy coatings come in a wide variety of colors and with or with out using flakes. These epoxy coatings for driveway, patios, garage floors, are uv and chemical resistant. For proper epoxy coating applications all concrete surfaces are ground down to virgin surface to allow for best adhesion. This method is what we use when installing any epoxy floor.

Epoxy coating is known for its strength; it is the most highly used and highly recommended floor covering system you can acquire. There are many manufactures of epoxies and for the majority they all have the same molecular make up. Various are of non chemical (water base) type and these are not as good for a commercial use as in the private sector. Home owners often like the garage floor in their home to have a beautiful epoxy floor. A water base is ok for this type of application as it doesn’t get the heavy traffic like on a roadway. If applied correctly the water base will last a few years and have to be touched up in some places. If solvent base is applied, it has proved to be a superior product lasting much longer and more durable.

Garage Floor Epoxy Coatings

There have been many occasions where the home owners have removed and poured back their garage floor because of a crack just to have it crack again. Because the slab is inside it rarely will sink down or sag, however it could crack in places, so the concrete is not bad it just needs cosmetics to make it look better. Not to say it’s dreadful but just not as good as it can be.

That’s where the repair comes in to play, instead of taking the slab out and replacing it, a very cost helpful way to repair it is Epoxy Floor Covering. (Tip#1- get a hold of a professional to see if it can be applied on your project.) When you are ready, there are many colors to choose from although some colors have to be ordered as of their rarity. Virtually any color is available at some point. Most common are “natural” color s these are grey, black, tan or that type of color in some fashion. Occasionally you will see shop floors and custom garages that’s had a Epoxy floor installed, custom work as you know is pricy and for good reason as the work needs to be flawless.(tip#2-if it sounds too good to be true..It probably is.) The custom epoxy floor can take many hours to complete, it could have pictures inlaid or drawn onto it with another shade of epoxy. It could be a multi colored floor with borders or a stencil of some sort.

Epoxy Coatings Phoenix The colors and choices for an over the counter brand tend to limit you, plus it’s not a commercial product. Although with very good floor preparation, it should turn out and last three to five years. With this hot climate our tires get blistering hot, this type will occasionally stick to your tires. After a good night sleep, you get in your car,  back out of the garage and take your floor covering with you (tip#3-try not to do this with the less expensive products.) that’s a real bummer when you spent your hard earned money on it. A commercial grade is designed to with stand more extreme issues. Of course it’s only as good as the contractor that’s installing it.

The speckled look from the less expensive products is very popular nowadays, mainly for its affordability. A knowledgeable repair man can perform this as well as epoxy coating contractors. These are designed for a crafty homeowner. There are instructions inside that can guide you. The Epoxy has a workability time so if you start you can t stop. Be sure that your prepared, if you are not, you will have a disastrous event that will not end up good at all. In some cases a professional is the best decision. In this economy the prices of the building contractors have dropped, it’s a good time to have this kind of work done. Especially try to find a contractor that has a bunch of years of experienced in this field. It’s also a good idea not to apply it when it’s to cool out, it is a plastic after all, plastic is brittle when frozen but set it in the sun and it becomes pliable, enough that you can actually stretch it.

Epoxy flooring can be a very beautiful addition to your home, shop, or where ever the concrete needs a fresh new look in addition the value of the home as well. It’s imperative to have knowledge before hand and make sure the right contractor is performing. Repair work like this is fast growing here in the valley as folks are watching how they spend their money, but when you want something done to your property that’s special, you want it done right and without incidents. As it should be.

We Service

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