Post on 10-Oct-2020
sk ten different architecture,
design, building, or specifica-
tion professionals what
“green” means with regard
to building materials and
finishes, and there’s a
good chance you’ll get
ten different answers.
The same goes with manufacturers of
products used in design and construction:
• Low VOCs
• Non-toxic (non-HAPs) content
• Sustainability (itself the subject of con-
siderable variation in interpretation of the
term’s meaning)
• Performance/durability
• Long service life
• Low carbon footprint
• Favorable lifecycle implications
So what is the building professional
to do? Try to balance the various criteria?
Focus on the environmental friendliness
of materials? Give precedence to perfor-
mance, durability, and service life? Follow
the supply chain and seek out the lifecy-
cle champion?
In this report, JAC seeks to shed some
light on this current quandary, while
focusing on one specific aspect of the
building—the concrete floor. We won’t
presume to arrive at an ironclad, defini-
tive conclusion on “What Green Means”
with regard to concrete floor coatings and
treatments, but we will at least examine
some of the important factors that might
be weighed in assessing the various tech-
nologies used to protect, color, and deco-
rate these increasingly important surfaces.
Concrete: Inherently green?In the view of many in the building and
design community, floors of concrete left
exposed (no floor covering on top) enjoy
a natural advantage in the green- and sus-
tainable-building hierarchy. Concrete, this
thinking goes, is inherently durable, long-
lasting, and hard wearing. Minus a cover-
ing on top such as tile, carpet, or sheet
flooring, the concrete floor—whether
stained, polished, coated, or integrally
colored—generates little or no waste
thanks to the lack of a need for periodic
replacement.
The manufacture of concrete also can
make use of industrial byproducts such as
fly ash from coal combustion, and con-
crete can itself be recycled and reused as
aggregrate in new concrete, as backfill, or
12 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008
The definition
of sustainability
carries range
of implications
for floor coatings
and treatments
By Joe Maty, Editor, JAC
Awhatever that meansGoing green,
Photo courtesy of Crown Polymers
Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008 13
as road base. In addition, the primary
ingredients in concrete—cement, sand,
and aggregrate—typically originate from
the local or regional area of the ultimate
end use, meeting another sustainability
objective due to reduced transportation
needs.
If concrete does, indeed, merit at least
some credit as a sustainable building
material for these reasons, the question
facing the green-minded specifier, design-
er, or owner then becomes, how can the
concrete floor be altered or treated to
meet design objectives while maximizing
aesthetic and performance aspects of the
floor?
In search of answers, JAC in this issue is
launching into a discussion of “What
Green Means” with regard to concrete
treatments and coatings, focusing on the
various types of materials and processes
involved in protecting and decorating the
concrete-floor surface. In addition, we
will attempt to enlist the expertise of
authorities in the sustainable building
and design community to gain a greater
understanding of the meaning of green
in this context of the concrete floor.
Concrete polishinggets positive ‘green’ reviews
The concrete-polishing process, in which
special chemical “hardeners” or “densi-
fiers” are applied to a machine-prepared
concrete-floor surface, is receiving posi-
tive reviews in terms of its contribution
to sustainable design. The technology is a
relatively recent development, having
made its debut in the 1990s.
The process starts with the “opening
up” of the concrete surface with grinding
machines using diamond-impregnated
discs, followed by application of a hard-
ener/densifier formulation, which reacts
with the concrete. The job is completed
with additional grinding and polishing,
the optional addition of color with stains
or dyes, application of a sealer, and bur-
nishing to achieve a glossy surface.
In the wet-polishing process, applica-
tion of the hardener/densifier is followed
with wet vacuuming. For the dry-grind-
ing process, which employs a lithium sili-
cate hardener, little or no cleanup is
required. Different color approaches can
be used with polishing, including integral
coloring of the concrete mixture (in the
case of new installations) or application
of stains or dyes to the densified con-
crete. A clear topcoat or sealer is also
applied in many cases, and a final touch
is polishing with a high-speed burnisher.
Dwayne Fuhlhage, regulatory affairs
director for PROSOCO Inc. and a certified
hazardous materials manager, says his
company’s polished-concrete materials
offer a combination of low VOC content
and functionality that contributes to the
floor’s durability, appearance, and perfor-
mance—translation: a positive sustain-
ability profile.
PROSOCO’S entry in the concrete-pol-
ishing marketplace—the Consolideck
process—is built around the use of lithi-
um silicate hardeners, which Fuhlhage
says accomplish the hardening and den-
sification of concrete with essentially no
waste generation. The lithium silicate
hardener/densifier is applied to the pre-
pared concrete surface and allowed to
“dwell” for 15 to 20 minutes, penetrating
Photo on facing page and at right and below: Makers of concrete coatings, stains, concrete-polymer overlays, and other treatments havemade strides in greening their product offerings with waterborne, 100% solids, and zero- and low-VOC technologies while seeking to
retain or enhance sustainability as defined by performance and durability.
Photo courtesy of Crown Polymers
Photo courtesy of Richard James Specialty Chemicals
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the concrete surface. The densification
reaction occurs quickly and completely,
leaving no residue for cleanup, he says.
Fuhlhage says polished concrete com-
pares favorably to other flooring materi-
als in sustainability terms, citing as an
example the use of linoleum. While
linoleum is thought of as being “green”
due to the renewable nature of its com-
ponents, Fuhlhage points out that the
supply chain carries a lengthy geographic
reach—as far as the Pacific Rim region for
jute, and the Mediterranean area for cork.
Fuhlhage says PROSOCO emphasizes
that concrete and masonry are sustain-
able substrates, but only with proper
maintenance and care.
Paul Grahovac, a LEED accredited pro-
fessional (AP) with PROSOCO, says pol-
ished concrete floors do require ongoing
maintenance, but he says this aspect of
the technology is relatively simple, with
application of a special cleaning formula
that includes a small amount of the hard-
ener/densifier product. The cleaner can
be applied by mop or with a floor-clean-
ing machine or sprayer. The cleaner actu-
ally reinforces the densification effect, he
says.
L.M. Scofield Company, another player
in the concrete-treatment field, offers all
three of the major types of hardener/den-
sifier chemistries: lithium silicate, sodium
silicate, and potassium silicate. Cam
14 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008
Makers of concrete coatings, stains, overlays, and othertreatments—companies such as Sherwin-Williams, CrownPolymers, Richard James Specialty Chemicals, andmany others—can make a strong case that they havemade great strides in greening their product offeringswhile seeking to retain or enhance sustainability asdefined by performance and durability.
The following is a sampling of some of these tech-nologies. These are only representative examples ofproduct offerings for concrete floors; this category ofproducts is varied and extensive.
Butterfield Color Inc.•Renovatio™Opaque Concrete Stain, a polymerized(non-acid) stain that penetrates and bonds with theporous concrete substrate•Renovatio Translucent Accent Stain•Elements Transparent Water-Based Stain, a nanopig-ment non-acid stain that penetrates the concrete sub-strate to create translucent color variations similar toreactive acid stains
Crown PolymersThe company’ s tagline, “All Our Colors are Green,” isa reference to a zero-VOC, 100% solids product line ofepoxy and polyurea coating and terrazzo systems. Theproduct line includes the following.•Polymer overlay, decorative-floor overlay, and epoxy
terrazzo systems Crownspatter™, CrownHybrid™,CrownQuartz™, CrownImage™, CrownStone™, CrownAccent™,CrownFlake™, CrownChips™, CrownShield™, Crown NaturalStone™, Crown Thin-Set Epoxy Terrazzo™•Epoxy, polyurea, and polyurethane topcoats CrownClear™and CrownPro™
GoldenLook of Texas•GoldenLook Epoxy Stone System 100% solids epoxyaggregate resurfacing system
Key Resin Company•Key Quartz B-65 and B-125 100% solids epoxy/coloredaggregrate decorative resin flooring•Key Epoxy Terrazzo 100% solids decorative epoxy/aggre-grate flooring
L&M Industries LLC•Sim Stain waterborne simulated acid stain concrete stain
Quality Systems Inc.•PermaCrete®waterborne bag mixes, sealers, epoxies,urethanes, cleaners, and crack-repair products
Richard James Specialty Chemicals Corp.•StoneClean™Concentrates, formulations for cleaning,maintaining, or stripping sealed and unsealed stone, tile,brick, concrete, and cementitious surfaces
New shades of green
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Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008 15
Villar, the company’s director of market-
ing, calls the lithium-silicate technology a
“top of the line, true architectural-level
densifier.”
But manufacturers of the densifier
products aren’t alone in touting the
green/sustainable merits of the concrete-
polishing technology. Alex Wilson, exec-
utive director of BuildingGreen.com, has
given the technology a ringing endorse-
ment. BuildingGreen.com is an influen-
tial voice in the green-building commu-
nity, and is an independent publishing
company that researches and reports on
green design and building methods and
materials. The company publishes
Environmental Building News and the
GreenSpec Directory, and offers the
BuildingGreen Suite of products to its
subscriber members.
In an article published in Environ-
mental Building News in 2006, Wilson
concluded that polished, densified con-
crete constitutes a “significantly better
alternative” to coatings and waxes, in
large part due to the relative permanence
of the densified and polished concrete
surface.
Wilson gives the densifying/polishing
technology sustainability points for
durability, UV resistance, ease of main-
tenance, and the concrete floor’s “struc-
ture as finish” condition, with no over-
lay, topping, or additional floor cover-
•StoneLok™water-dilutable polyurethane floor coatingand StoneLok MLT Plus waterborne penetratingpolyurethane sealer•TekSeal™PRO One-Pack fast-dry waterborneprimer/sealer
Smith Paint Products•Smith’ s Color Floor waterborne acrylic decorative stain•Smith’ s Green Clean, a noncorrosive acid cleaner forconcrete•Smith’ s Base Boost, a silicate-based, no-VOC liquid for-mulated to densify or fortify the concrete floor; can beadded to the coating product to enhance the chemicalbond with the substrate
PPG Industries Inc.PPG offers MegaSeal Green, a comprehensive industrialflooring product line that includes products for light-dutycommercial to institutional to heavy industrial environ-ments. The coatings products—primer/sealers, topcoats,self-leveling coatings, high-performance urethanes, andepoxy repair materials—include•100% solids, zero-VOC epoxy coatings and repairmaterials;•zero-VOC waterborne epoxies;•low-VOC epoxies; and•high-solids, low-VOC urethanes.
The Sherwin-Williams Company, General Polymers®The company offers an extensive range of seamless
flooring systems, terrazzo, coatings, and repair productsfor commercial, institutional, and industrial applica-tions, all with VOC levels of 100 grams per liter or less.Major products for commercial and institutional usesinclude the following.•Thin-Set Epoxy Terrazzo #1100•FasTop urethane cement floor topping•Ceramic Carpet epoxy quartz floor topping•Epo-Flex systems flexible epoxy membranes
Vexcon Chemicals Inc.StarSeal EF (Eco-Friendly) products (low odor, low VOC)•StarSeal EF acrylic coatings and stains•StarSeal EF Primer and Starseal EF Epoxy•StarSeal PS Systems hardeners and densifiers•StarSeal EF protective treatments: EF Weather Seal, EFWaterproof, and EF Weather & Stain Guard•StarSeal EF Degreaser and Cleaner, StarSeal EFStripper
Westcoat•EC-31 Clear Epoxy Topcoat, 100% solids, zero-VOCclear topcoat or binder•SC-41 Water-Based Sealer, hybrid acrylic/urethaneclear concrete sealer and glaze, under 100 grams perliter VOCs•SC-70 Stone Glaze, acrylic lacquer sealer, formulatedwith non-VOC solvents•SC-35 Water-Based Stain, water-based with low toxicity
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16 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008
ing required. This provides economies
and reduces raw-materials consump-
tion and environmental impacts, he
says. Also a plus are the negligible or
nonexistent VOC emissions from the
products used, meaning indoor air
quality is not adversely affected.
Other positives, Wilson says, are resis-
tance to staining from spills due to the
reduced porosity of the densified con-
crete; absence of flammables; and
increased reflectivity, resulting in the
potential for reduced need for lighting.
The thermal mass of the concrete also
enhances passive solar heating and night
“flushing” for cooling effect, he adds.
As with other technologies, however,
Wilson observes that polished concrete
isn’t without its limitations. The
acoustics may be bouncy, and the ther-
mal conductivity of concrete can result
in cool-season chill.
In summary, Wilson predicted that,
with its advantages, polished, densified
concrete floors “will become the flooring
option of choice for hard-surface flooring
in schools, retail stores, industrial build-
ings, and a wide range of other commer-
cial buildings.” He also forecast growth
in applications in residential settings.
Building on the polishing portfolioPerhaps sensing that concrete polishing
is gaining momentum in the design and
building community, manufacturers are
looking to develop technologies that
can play a part in this growth industry.
An example: a formulated water repel-
lent developed by Dow Corning Corp.
that is marketed as a means to fortify
the resistance capabilities of the pol-
ished concrete floor.
The repellent product, carrying the
name Dow Corning IE 6694, is a low-
VOC, dilutable silane/siloxane blend,
says David Selley, technical service spe-
The concrete-polishing process, in which special chemical harden-ers, or densifiers, are applied to a machine-prepared concrete-floor surface, has received positive reviews as a sustainable-
design technology. Photo courtesy of PROSOCO Inc.
cialist with Dow Corning’s Building Materials Protection
Group.
Selley says the silane/siliconate chemistry is designed to fur-
ther reduce the porosity and boost the water repellence of the
densified and polished concrete surface, enhancing resistance
to oil, grease, and other stain-causing agents.
Can anything brake the polishing express?But before the concrete densifying/polishing express leaves all
other concrete treatment and coating systems in its wake,
developers and manufacturers of these more traditional tech-
nologies may raise a cautionary flag. Issues that should get
consideration when deciding on the correct concrete-floor
treatment approach, these manufacturers say, include the
severity of the service environment, the importance of uni-
form color and color matching, slip resistance, and the techni-
cal challenge of getting the desired result with the relatively
labor-intensive densification/polishing process.
Bruce Maier, chief scientist of coatings manufacturer
Richard James Specialty Chemicals, says “grind and shine”—
his term for the concrete densification/polishing process—“as
a general rule, is extraordinarily energy and labor intensive if
you’re trying to get dense colors.
“Grind and shine is an art form, and variation is an issue,”
Maier says.
Richard James Specialty Chemicals is a manufacturer of low-
VOC, waterborne concrete-floor coatings based on epoxy, ure-
thane, and acrylic chemistries. The company also offers inte-
gral colors for concrete. Maier says the company has sought to
create advanced materials that offer a range of color and effect
Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008 17
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Design and color techniques involving the concrete densification/polishing process include the useof integral coloring of the concrete mixture (in the case of new installations) or application of
stains or dyes to the densified concrete. Photo courtesy of PROSOCO Inc.
JAC
18 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008
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features, are highly impact and chemical resistant, and are
characterized by a high degree of adhesion to the substrate
facilitated by a proprietary organosilane component.
“Where you want to get the job done fast and you don’t
have a lot of time—those are the situations where grind-and-
shine systems aren’t applicable,” Maier says. He cites as exam-
ple the floor of a retail sporting-goods store where one of his
company’s products was used. The client wanted the entrance
to the ski area of the store to be a specific ice-blue shade, with
a durable, anti-skid surface. In this case, a coating fit the bill.
Lonnie Salyers, vice president, technical operations, for The
Sherwin-Williams Company’s General Polymers brand of floor
coatings and systems, says high-performance urethane and
epoxy coatings offer the performance needed “anywhere
where chemical resistance and physical-abuse requirements
are factors.” These types of resinous systems offer resistance to
impact and chemical agents ranging from food and beverage
stains to harsh chemicals and oils.
Floyd Dimmick, technical director of Crown Polymers, also
a manufacturer of floor-coating and polymeric overlay sys-
tems, echoes Maier’s assessment of factors that may limit the
applicability of concrete densification/polishing. “It takes mul-
tiple polishings to get the desired result,” he says. “Also,
defects or weakness in concrete are an issue with polishing,
where you have pitting and degradation. You can deal with
this with overlays.
“We get a lot of partially finished polishing jobs,” Dimmick
says, referring to densification/polishing projects that went
awry or otherwise didn’t pan out. He contends that a high-
performance epoxy polymer concrete can match or surpass
densified/polished concrete in durability and service life.
“That is sustainability,” he says. “Concrete polishing has
found a market in high-end settings, such as shopping malls,
retail stores—where the look is the selling point.”
Although his company makes densifiers for concrete polish-
ing, Cam Villar of L.M. Scofield agrees that the polishing
process isn’t meant for every concrete floor project. “Polishing
is more labor intensive,” he says. The condition and age of
existing concrete floors also dictate whether the surface can be
brought up to a condition that will meet the performance and
appearance objectives of a polishing project.
L.M. Scofield also manufactures concrete stains and integral
coloring, which can be used to color and decorate concrete
with or without employing the densification/polishing
process.
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