5 Effective Solutions for Different Concrete Problems

June 11, 2018

General Coating & Polishing

There are always certain challenges to overcome when it comes to deciding which concrete coating or polishing option is right for different workspaces. While many cases are relatively straightforward, there are certain instances that require creative solutions that stand up to unique business or personal needs. The following are five examples of different concrete coating or polishing solutions for different concrete problems.

Concrete Coating or Polishing Solutions for Unique Business Needs

Problem 1

A Parts Department was moving into a 2000-square-foot space featuring a significantly distressed floor. The existing concrete was rough and had noticeable voids. The company didn’t want concrete coating, due to heavy foot traffic. They needed an extremely durable solution that would stand up to daily wear and tear.

Solution 1

A mechanically polished concrete floor was the correct solution in this case. However, the voids and defects in the existing floor needed to be addressed first. To fill the voids, the floor was skim coated with quick-drying polycrete. The floor was then mechanically polished. This process created a smooth, dense, virtually maintenance-free floor. It was also comparatively inexpensive compared to coatings in this particular situation.

Problem 2

For the past few decades, a large shop was used to restore classic muscle cars. Recently, the decision was made to only use this shop as a showroom to display these restored cars. Of course, the shop floor showed obvious signs of the years of restoration work. Instead, the client wanted an attractive and light-reflecting floor to show off his hard work.

Solution 2

We decided on using a hybrid polyurethane. This concrete coating solution is durable and won’t delaminate over time. It can also be easily repaired in the future. Specifically, we used a light gray hybrid polyurethane, with black and white flakes. These flakes successfully camouflage any flaws and help hide dust. The finished floor reflects light beautifully and helps show off the cars. Plus, it cleans up very well.

Problem 3

A manufacturing and processing center has a room used to thaw items in water-filled vats. Once thawed, valves on these vats are opened and water freely flows out onto the floor. The constant flow of water caused the existing floor to be quite slippery. Plus, the temperature of the room also led to occasional ice build-up. On top of this all, the floor is cleaned daily with 140-degree water, and fork lifts are used to move the vats around. So, in summary, this company needed an anti-slip floor capable of withstanding thermal shock and forklift traffic.

Solution 3

Durable polycrete was used in this case. Approximately 800 pounds of quartz crystals were then broadcast to refusal by hand. After curing for around 16 hours, the leftover quartz was scraped off, and a polyaspartic top coat was used to encapsulate the quartz. This top coat is extremely durable and cures fast. Thus, it allowed the company to resume normal activity in a short timeframe. This unique concrete coating option ultimately provided traction, durability and the ability to stand up to extreme temperature change without fracturing.

Problem 4

A manufacturing facility wanted concrete coating in a 3000-square-foot space. They wanted it to look nice for clients, while also withstanding moderate-to-heavy foot traffic and forklifts. They also needed it finished quickly.

Solution 4

After the last shift of the day, we started work. We decided on a polyaspartic coating, with a light aggregate (black and white flakes). The entire process included grinding, prep work, coating, applying the aggregate to refusal, cleaning and finishing with a top coat. By the very next morning, the client was able to resume work on their attractive and durable floor.

Problem 5

Like many older buildings, an area college has terrazzo floors. Historically, these floors were topped with a heavy sealer and three to four coats of wax. This method requires constant, regular maintenance. In fact, they need to be completely stripped every two years. The client just did not have the manpower to properly care for their existing floors.

Solution 5

We stripped and mechanically polished the terrazzo floors. The floors now look great and require minimal maintenance. This relatively simple solution saved the college unnecessary maintenance time and manpower.Every company has a unique problem when it comes to different types of concrete floorings. ‍

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8 Ways to Upgrade Your Concrete Floor

There are so many ways to upgrade your concrete floor from polishing to coating to engraving or staining. We love helping our clients pick out the right fit for what they are looking to accomplish. Sometimes it’s a bit overwhelming to choose what to do with your concrete flooring. Here are 8 ways you can upgrade your concrete to protect and/or enhance it with a little explanation about each technique. We hope this helps when deciding what to do with your next project!

Mechanical Polishing

Mechanical polished concrete is a process that takes abrasives (diamonds) and mechanically places scratches in the concrete. This scratching process uses finer grit abrasives to remove and replace the scratches with smaller and smaller micro scratches.

The objective is to refine the floor and take away the small scratches so that you see a reflection in the floor. This process can be achieved with older concrete, new concrete and/or coated concrete.

This process is considered to be the maximum refinement method, and can be considered the best long-term solution for polished concrete.

Topical Polishing

Topical polishing is similar to the mechanically polished floor, but the course of action is shorter, and it leaves the floor at less than maximum refinement.

Most of the time the topically processed progression ends at a 200- or 400- grit step. These grits leave peaks on the top of the scratches that have zero lateral support. A topical sealer is then added and is placed into the gaps left by the scratching process. As the sealer settles and dries, it gives the appearance of being completely polished and is referred to as “polished concrete.”

This process is a much cheaper alternative to the mechanical process. The “topical polish” is exactly the same thing as putting on a coating. This method can be done with a burnisher, a floor scrubber and even a swing machine.

Decorative Epoxy Coatings

Epoxy floor coatings are hard wearing and durable solutions for both commercial and residential flooring. These floor coatings can be applied over concrete floors to provide a high performance and an attractive surface.

New technology now offers you the ability to choose almost any color. Metallic additives create a gorgeous surface and multiple colors can be randomly applied together revealing a swirling effect that is very unique and attractive.

Decorative Overlays

Overlays are a great option for concrete floors that are damaged or distressed. They are extremely durable and attractive. Overlays typically consist of a cementitious product, but some may be a combination of polyurethane and cement. They can be stained, mechanically polished, coated or stamped with any pattern you can imagine. Overlays are a great way to make an old concrete floor look brand new.

Dyes and Stains

The skies the limit when it comes to colorants. Multiple colors and patterns add to the beauty of your polished floor. There are a multitude of application techniques to add interesting effects when applying dyes and stains.

Engraving

We can incorporate engraving into your polishing process to provide borders and logos. Engraving can turn ordinary concrete surfaces into slate, tile, stone, brick and much more.

Hardeners and Sealers

Hardeners/densifiers are products that penetrate into the concrete surface and react with the Portland cement and fills the micro-pores. This reaction creates a very dense surface that helps with ease of cleaning, abrasion, dusting, staining, and overall wear of your concrete surface. These products do not change the appearance of the surface but can generate a sheen after burnishing and actually becomes harder the more you use the surface.

Sealers are an option for some floors. Depending on your needs it may provide a shiny surface that is easy to clean. All sealers will need to be reapplied at some point depending on wear and tear.

Final Notes

Performance Concrete Polishing is focused on providing services that are related to concrete surfaces. These services are appropriate for new and existing concrete. The majority of services we offer are oriented to improving the aesthetic appearance of these surfaces. Decorative concrete services are the hallmark of this company, and we’d love to help you out with your next project!