Concrete Visions has adopted, what we believe to be, the best processes for finishing and protecting
concrete floors. We continually educate ourselves on the finest products and systems available for
your surfaces. It is our desire to provide the absolute best value for you, our customer.
Should you have any questions following your reading about our process, please share them with
us at our contact page. We will look forward to answering them, and making you comfortable with
the process.
The basic process for polished and densified concrete has five aspects to it:
First we must utilize our experience and knowledge to establish the starting point for
your grinding. Some of the questions that we may need answered, either through
questions or visual inspection are: whether your concrete is old or new; are there any
existing chemicals or membranes that require removal prior to our dyeing or densifying;
is the floor stained, and if so, can we remove the stains either mechanically or
chemically; how flat is the floor and how flat do you want the floor; and most importantly, do you have educated and realistic expectations of what the floor can look
like, and what it will cost to achieve that look. Finally, you need to know what the true
performance aspects of the floor are – it will be high performance, but don’t let anyone
tell you that it is “bulletproof.”
Second: Diamond grinding and polishing of the surface generally requires that you
start with large grit diamonds in a metal matrix, followed by a succession of finer grit
diamonds in a resin-based matrix. As we grind the diamonds will create what we refer to
as a “scratch pattern.” Creating a consistent scratch pattern is a requirement of correct
grinding and polishing. The scratch pattern is similar to the highs and lows, peaks and
valleys of a mountain range. Each successive diamond step, when properly completed,
will lower the scratch profile by half. i.e. a 100 grit resin diamond is followed by a 200
grit resin diamond, and a then a 400, on up to 800 -1500 -3000 depending on the final
shine you are trying to achieve, along with the type of environment the floor is located.
At each level of grit you visually start to perceive a gloss as light starts to be reflected
vs. refracted. A polished floor has two visual qualities: 1) clarity evaluates the crispness
of your reflection and is created by properly performing your first two steps when you
remove laitance and blemishes, along with flattening; 2) polishing is the final surface
sheen that you receive as you continue to lower the profile of your scratch pattern. For
reference, a 400-grit resin finish is generally equivalent to a matte finish where you see
reflection at an angle, but not straight down. Note: A gloss meter should only be
utilized to evaluate the objective change from start to finish, or between grits, and not as a subjective tool. All concrete is a natural product and there is too much natural
variation from pour to pour or even within individual slabs to fairly use the meter as a
specification tool.
Third: If you are planning to have your floor dyed or stained always perform a test first
to establish a representative sample. Both colorants are translucent and will transmit
any imperfections in the floor, and know what the difference is between dyes and stains.
Dyes are imparted into the floor in either an acetone or water-based solution and can be
applied to produce a relatively monolithic appearance, whereas acid stain is an
uncontrollable reaction with the concrete that creates a variegated and mottled
appearance. Note: Acid Stains require neutralization prior to chemically densifying or
you will experience a chemical reaction that requires grinding to remove.
Following the dyeing and/or acid staining, it is now time for chemical densifying and
hardening. Unlike traditional dyed and stained concrete that requires a clear finish to protect the surface, polished concrete, when hardened properly, will never need a topical
coating.
Fourth: Chemical densification is a must if you want to retain the benefits of your
polished floor. The chemical densification, through a chemical reaction between the
densifier and the calcium hydroxide in the concrete, not only eliminates the natural
dusting of concrete, but also hardens the floor and makes it more repellent to spills.
When concrete cures it creates CSH (calcium silicate hydrate), which is the strong
cementing component of concrete, and CH (calcium hydrate) which is the softer material
at the surface of the concrete. The chemical reaction that occurs between the CH and
densifier mimics the hydration process and creates additional CSH, thus increasing the
strength of the concrete slab, along with protecting any stain or dye that has been
properly applied. Different types of densifiers exist and can produce good floors, but it is
important to get adequate coverage to receive your expected results.
Fifth: Your long-term satisfaction with your floor is only as good as your commitment
to establishing and carrying out a proper maintenance program. CVI’s strength is that
we provide you with a complete package; from initial flooring evaluations to providing a
individualized maintenance program that addresses maintenance frequencies, proper
walk-off mat protection, and equipment and cleaner recommendations. An improperly
maintained floor can be as detrimental as no maintenance and CVI, by working with our
manufacturing partners, removes this hurdle for you. An effective maintenance program
ensures your satisfaction with your flooring choice, along with extending the life of your
floor.
