Achieving High-Quality Concrete Finishes Through Efficient Diamond Tooling

Achieving a high-quality concrete floor finish hinges on several factors, including the right tools and efficient diamond tooling. The initial cut is often the most time-consuming, especially when removing thick coatings. While metal bond tools can sometimes be used, aggressive options like PCD tools (with one or two poly-crystalline diamond segments, with or without sacrificial bars or a metal button) are often necessary. This approach was adopted by Robles Concrete Services, a Georgia-based concrete polishing contractor, to remove a thick coating during a recent project for Resilux America, a PET-plastics manufacturer in Pendergrass, GA.

Resilux Revamps Plant with Honed and Dyed Concrete Floors

Resilux, a PET-plastics manufacturer, selected a honed and dyed concrete finish for its plant renovations. Robles Concrete Services, a Georgia-based flooring contractor, was contracted for the project, with the first renovation recently completed.

The 44,000-square-foot building, previously owned by a construction equipment company, presented several challenges. These included:

• Grease contamination: The concrete floor was heavily ingrained with grease.
• Thick coating removal: Approximately 13,000 square feet required the removal of a 5mm thick coating.
• Bolt removal: Over 200 bolts protruded from the floor, posing a risk to tools and requiring careful removal.

Robles Concrete Polishing Approach:

• Grinding Equipment: LAVINA grinders (32-inch, 30-inch propane, and 25-inch) were utilized.
• Initial Grinding:
  • PCD diamond tooling from Superabrasive was used for aggressive removal of the thick coating, although it resulted in deep scratches.
  • Subsequent grinding with 14-grit metal bond diamonds was necessary to address these scratches.
  • Superabrasive's QuickChange tools, available in various bonds for different concrete hardnesses, were employed.
• Mid-Grinding:
  • 30, 50, and 120-grit metal bond diamonds were used for progressive refinement.
  • Superabrasive's Calibra ceramic discs (100-grit, 3-inch Velcro-backed) were effective in removing remaining scratches after the metal bond steps.
• Areas without Coatings:
  • Superabrasive's HD Copper discs were used for fast and efficient cutting without causing deep scratches. Wet grinding was employed with diligent cleaning after each pass.
  • 200 and 400-grit HD resin pads (dry) were used for further refinement.
  • Prosoco's densifier and Gem tone dye were applied.
• Final Polishing:
  • LAVINA 36-inch propane burnisher (LB36G-S) was used with ShinePro Buff pads (3,000-grit diamond pads) for micro-polishing and cleaning. ShinePro Buff, part of Superabrasive's ShinePro line, enhances shine without removing sealer or causing orange peel effects.

The Next Project:

The second plant renovation, scheduled for the second quarter of 2016, will utilize the same floor finish. With no coatings to remove, Robles Concrete anticipates a faster turnaround time. The process will involve:

• Grinding: LAVINA grinders with Superabrasive's HD Copper discs (wet grinding) using 50, 100, and 200-grit.
• Color and Densification: Application of color and densifier.
• Final Polishing: Superabrasive's V-Harr premium polishing pads (400-grit).

Reach out if you are interested in concrete polishing in the Atlanta GA area.