Bonded abrasive polished concrete - PaintSquare

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AIA CES Presentation

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An In-Depth Look at the Polishing Process for Better Design and Implementation

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Monday, December 9, 13

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Copyright MaterialThis presentation is protected by U.S. and International Copyright laws.

Reproduction, distribution, display and use of the presentation without written permission of the speaker is strictly prohibited.

Copyright © 2012 Concrete Polishing Association of America. All Rights Reserved.©AIA/CES 2012

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AIA CES Presentation3

CPAA is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members.

Certificates of Completion for both AIA members and non-AIA members are available upon request.

This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product._________________________________________________________________

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.


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An Introduction to the CPAA


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Function and Purpose of the CPAA• Developing Industry Standards for Polished Concrete

• Defining Procedures and Standards for Contractors

• Defining Industry Terminology and Definitions

• Assisting General Contractors, Architects, and Owners in the selection of quality applicators

• Bringing Craftsmanship and Professionalism to the Industry through contractor training, evaluations, and accreditations

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Benefits of Polished Concrete


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Permanent Flooring SolutionPerformance and appearance will retain greater consistency throughout the life of the surface because, unlike other finishes that rely on topical coatings (surface coated concrete), the concrete polishing process exposes and enhances the strength and durability inherent to the concrete. The result is a beautiful, durable, and efficient surface which eliminated the need for carpet, tile, or coatings that require expensive replacement, maintenance and harsh cleaning chemicals.

Low MaintenanceWithout superficial coatings, concrete polishing leaves you with a product that does not peel, chip or flake over time, making regular maintenance simple while saving time and money.

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Energy ReductionPolishing Concrete to a high gloss (Level 3-4) increases the efficiency of installed lighting due to extremely high DOI (distinction of image).

Polished Concrete has the advantage of being able to utilize the natural thermal mass of concrete, allowing for more efficient heating and cooling leading to a smaller carbon footprint.

Polished Concrete has the advantage of low maintenance, eliminating the cost of Energy to power cleaning equipment

• Chemicals• Labor• Downtime• Periodic replacement / restoration

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Abrasion ResistantPolishing Concrete has an increased abrasion resistance due to:

Refinement - the bonded abrasive polishing process refines the concrete surface on a microscopic level to minimize the peaks and valleys which decreases the chances of scratches, wear patterns, and trapping debris. This increases the abrasion resistance by approximately 6%.

Densifier - Silicate densifiers (lithium, potassium, sodium, magnesium) react with the calcium hydroxide within the concrete to create a crystalline structure known as calcium silicate hydrate. This chemical reaction increases the abrasion resistance of the wear surface by approximately 20%. Introduction of pozzolans, such as fly ash or fumed silica (amorphous / colloidal), also increase the density and abrasion resistance of concrete.

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Life Cycle CostPolished Concrete often is less expensive than other flooring options. Long term value is realized in long term replacement / restoration, maintenance and energy savings.

Polished Concrete is not maintenance free as some have promoted. However, the routine maintenance is significantly lower and easier than other flooring options.

Maintenance generally requires routine cleaning (auto-scrubber with mild PC cleaning solution) and occasionally buffing with diamond impregnated maintenance pads. Associated costs with stripping, top scrubbing, refinishing, re-coating, and deep cleaning are eliminated.

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Life Cycle CostFactors that influence routine maintenance schedules and costs are:

• Amount and type of traffic• Amount and type of contaminant (soil)• Entrance matting• Maintenance procedures• Guard / Stain protectants

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Life Cycle Cost

$5,000

$128,333

$251,667

$375,000

5 years10 years 20 years30 years

Polished Concrete Coatings VCT

Vinyl Tile$375,000

30 Year Cost

Coatings$275,000

30 Year Cost

Polished ConcreteLess than $150,00

30 Year Cost

Figures taken from American Terrazzo Association and Concrete Construction MAgazine. Doe not include initial installation. Includes re-installation at 10 year intervals for VCT and 5 year intervals for coatings. Polished Concrete periodically maintained and refreshed for $0.50 /square foot or lower, annually.

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Life Cycle Cost

Bonded Abrasive Polished Concrete that has been properly installed is more durable and has a longer life cycle before restoration than any other floor covering available.

Various flooring materials will look great with first installed. As they begin to wear with service, the appearance slowly degrades even with frequent maintenance.

Bonded Abrasive Polished Concrete does not go through this frequent cycle. Bonded Abrasive Polished Concrete is permanent, long lasting, and durable. After a significant duration (often 10-15 years of service) a one to three step Hybrid Polishing Process is all that is required to restore the original appearance.

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Functionality

Bonded Abrasive Polished Concrete:

• Allows for vapor transmission (dyes are MVE sensitive)• Concrete dusting is eliminated 100%• Increased impact resistance• Resist tire marks (forklift and vehicular traffic)• Refined surface that reduces vibration (less equipment repair)• Little or no down time during installation

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Sustainable Design

Bonded Abrasive Polished Concrete:

• Has no VOCs• Eliminates the use of harsh cleaning processes-thereby eliminating

other high VOC chemicals• Better indoor environmental air quality• Reduces heating and cooling loads • Reduces lighting requirements• Reduces disposal of refuse (carpet, vct, linoleum, etc in landfills)

• Overall reduces Environmental Footprint of building construction

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Introduction and Overview of Polished Concrete


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Classifications of Polished Concrete Include:

• Bonded Abrasive Polished Concrete

• Burnished Polished Concrete

• Hybrid Polished Concrete

The act of changing a concrete floor surface, with or without aggregate exposure, until the desired level of finished gloss is achieved by using one of the listed classifications;

POLISHED CONCRETE


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Bonded abrasive polished concrete - The multi-step operation of mechanically grinding, honing, and polishing a concrete floor surface with bonded abrasives to cut a concrete floor surface and to refine each cut to the maximum potential to achieve a specified level of finished gloss as defined by the CPAA. This yields the most durable finish and requires the least maintenance.

POLISHED CONCRETE


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Burnished polished concrete - The multi-step operation of mechanical friction-rubbing a concrete floor surface with or without waxes or resins to achieve a specified level of finished gloss as defined by the CPAA. This operation yields a less durable finish and requires more maintenance than bonded abrasive polished concrete.

POLISHED CONCRETE


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Hybrid polished concrete - A multi-step operation, using either standard grinding / polishing equipment, lightweight equipment, high speed burnishing equipment, or a combination of, to combine the mechanical grinding, honing, and polishing process with the friction rubbing process by utilizing bonded abrasives, abrasive pads, or a combination of, to achieve the specified level of finished gloss as defined by the CPAA.

POLISHED CONCRETE


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Surface coated concrete - Surface coated concrete does not conform to the definition of polished concrete per the CPAA. It is the operation of applying a film forming coating to a concrete floor surface to achieve a specified level of finished gloss. Durability depends on the quality of the chemical coating used, the amount of traffic across the floor, and floor maintenance.

POLISHED CONCRETE


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The Polishing Process


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Most designs are capable of producing Processed / Polished Concrete- with production rate being the main differences.


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From one extreme to another


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Diamond Tooling

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Diamond Tooling

40 grit diamonds under a 10X loop

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• Are the most significant tool in polishing concrete

• Require the craftsman to know how to use them in conjunction with the available equipment in order to unlock their full potential

• Come in many forms, shapes and sizes

• Are made out of various materials (bonding) and will vary in hardness

• Can be categorized as coarse, medium, or fine and for soft, medium, or hard concrete


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• Grit refers to the particle size of the abrasive that is imbedded into the bonding material.

• Grit particles are measured in Microns.

• Hard concrete will require a softer bonding.

• Soft concrete will require a harder bonding.


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Fine Abrasives• Abrasive is bonded together in a resin bonding material

• Resins abrasives are made of • poly-phenolic and ester-phenolic resin (resinoid) for wet & dry use• thermoplastic-phenolic resins for dry use only • resins vary in hardness and thermal properties compared to others of the

same kind

• Just like metals, resins undergo different processes• i.e. 'old time' injection-molding, pre-sintering, cold and/or hot pressing

• Grit ranges from 50 grit (low) to 3000 grit (high)


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400 grit diamond matrix under a 10X power loop

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• Diamond abrasives are designed to mechanically abrade the surface

• There are three levels of abrasion:

• Grinding• Includes abrasives up to 100 grit (metals or resins)

• Honing• Includes abrasives 100, 200, and 400 grit

• Polishing• Includes abrasive 800 grit and above


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• All grits create peaks and valleys.

• As you move up in grits, these peaks and valleys just get smaller and finer.

• The higher the grit, the smaller the peaks and valleys are, and the easier they are to remove.

• When diamond abrasives are used properly, you will achieve a surface that, on a microscopic level, will reflect light in a perfectly organized manner

• This is where you obtain clarity of reflection and depth

• Any remaining abrasions, scratches or imperfections will cause the light to refract back in an obscured, unorganized manner


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Grinding PolishingHoning

NOTE: Switching from a single/double segment diamond tool to a ten segment diamond tool allows the concrete surface to be refined as quickly as possible to obtain the best clarity of reflection. The more surface area a diamond abrasive has, the faster the surface of the concrete will be refined and the better the end result will be.


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• Each grit is designed to not only replace the abrasion/scratch pattern of the previous grit, but to continue on and fully refine its own abrasion/scratch pattern.

• Consequently, skipping a grit will leave abrasion/scratch patterns that never get removed from the surface.

• More refined = more abrasion resistant • The more refined a floor is, the more abrasion resistant the floor

becomes

• The fewer valleys left on a microscopic level, the less peaks there are for an object to catch on and create a scratch


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Maximum Refinement • The processes of polishing concrete is very technical in nature and

requires real craftsmanship.• Refinement goes beyond replacing the scratch pattern from one grit to

the next. Some contractors reduce refinement to the process of replacing the scratch pattern from one grit to the next. This is a misconception. Once the scratch pattern has been replaced from the previous grit, further refinement of the concrete should take place.

• Contractors need to understand and be able to explain what maximum refinement of the surface means.


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Maximum Refinement

• Just because two contractors have the same grit sequence specified the significant factor to take into consideration is that maximum refinement of each grit is performed.


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Project Info:Family DollarFlorida

Contractor:Polished Solution

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Project Info:Airplane HangerOklahoma

Contractor:Concrete Visions, Inc

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Project Info:Ewing IrrigationTexas

Contractor:First American Floor Co.

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Project Info:Residential GarageTexas

Contractor:First American Floor Co.

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• The RPM of the machine.

• The Weight of the machine.

• The Speed of the forward liner motion the machine is moving as dictated by the operator.

• The face/tread style of the abrasive.

• Hardness of diamond bonding.

• Planetary Movement – Active/Passive.

• Direction of planetary movement.

• The saturation of diamond grit in the bonding.

Factors Effecting Maximum Refinement:


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How Densifiers WorkMost densifiers are composed of:

• Colloidal Silicate• Lithium Silicate• Potassium Silicate• Sodium Silicate• Magnesium Silicate

or• Amorphous Silica• Colloidal Silica

Note* Silicate and Silicanate are similar yet yield different results. Silicanate reaction takes longer and becomes hydrophobic when complete.


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Liquid Densifiers – an Aqueous solution of SiO2 dissolved in the respective Hydroxide (see below) that penetrates into the concrete surface and reacts with the Calcium Hydroxide to provide a permanent chemical reaction that hardens and densifies the wear surface of the cementitious portion of the concrete.

• Sodium Silicate • Potassium Silicate • Lithium Silicate • Alkalis solution of Colloidal Silicates or Silica

All the above is the same chemistry varying only by the alkali used for solubility of the SiO2. NOTE:

1. The following products do not harden or densify concrete.a. Siliconate is a synonym for Sodium Silicate that is a solid without any water and therefore non reactive in the

reactions described above. b. Colloidal Silica SiO2 that is suspended only in H2O is non reactive as a densifier. c. Siliconates are sometimes a truncated descriptions for a Alkyl (organic) Alkali Metal Silicate which are water

repellents and react in the acid form of CO2 (Carbon Dioxide) and H2O (Carbonic Acid). These might be used as an additive in Silicate Solutions for early water repelling of the densifiers


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Benefits of Densifiers• Densifiers are a major component contributing to the significant durability

of polished concrete. The denser the concrete, the better the concrete can be refined to achieve higher gloss, better clarity and more abrasion resistance.

• Densifiers are commonly overlooked by the contractor as a contributing factor to the end results. Too often they are watered down or skipped in an effort to safe time/money which leads to poor results and additional labor.

• On average, Bonded Abrasive Polished Concrete can increase the abrasion resistance of regular concrete substrates by 26%. 20% of this is contributed by the proper application of densifier (until rejection) with the remaining 6% being contributed to the proper mechanical refinement of the concrete surface.


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Densifier

The application of a densifier will be dictated by the concrete. There are situations that may require densification before grinding starts.


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• Over time you will hear it is best to densify at any specific grit. Everyone has their own opinion. The fact of the matter is the concrete you are working with will determine when you densify.

• A very soft concrete may require you to densify before you even make the first cut.

• A good rule is to densify in-between your metal and resin grits.

• Remember that the denser the surface, the better result you will get. Also remember that your abrasives still need to be able to cut and refine the surface to its fullest potential.

Densifiers


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• Most are comprised of semi-impregnating chemistry derived from acrylics and/or latex.

• If applied correctly, will provide a small window of protection from surface stains and etching.

• If applied correctly, are not considered film-forming-but will increase the required routine maintenance.

• If applied incorrectly, they become film forming and create major maintenance headache.

• If applied incorrectly, they cover poor craftsmanship for a short period of time until the product is worn away.....then reveal the true craftsmanship of the contractor.

Guard / Stain Protectors


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• Some are comprised of penetrating products such as:

• Silane• Siloxane• Silicanate

These don’t offer as much surface protection, but offer better stain protection due to the hydrophobic nature. These can also require less frequent re-application and routine maintenance.

Guard / Stain Protectors


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Gloss• DOI (Clarity) ASTM D5767• Haze• Specular Gloss ASTM D4039• Scale 0-100

Testing / Quantifying

Profile• Profilagraph• Scale 0-50

Abrasion• Revolutionary Cycles• Scale 1-100

Slip Coefficient• ANSI B101.1• ANSI B101.3• SCOF Scale .47• DCOF Scale .35-.45


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Processing concrete to a polish is like sanding wood or buffing your fingernails. A course grit abrasive is used to start the process and progressive finer abrasives are used until the desired finished sheen achieved. During this process, a densifier is applied that makes the concrete extremely dense. The process may be done wet or dry.

There are two basic types of diamond tools – metal and resin.

A basic Polishing Process (grit sequence) would be: METAL - 70 and 120 - (transitional tooling) HYBRID - 50 and 100 RESIN - 200, 400, 800, 1500. 3000


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Health & Safety Concerns of Polished Concrete


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Health / Safety ConcernsIndoor Air Quality


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Health / Safety ConcernsSlurry Disposal


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Health / Safety Concerns


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Long Term Benefits of Polished Concrete


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Estimated Service Cycle

0

15

30

Bonded PC Hybrid PCBurnished PC Surface Coated

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Decorative64


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Durable and Versatile

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Cost Effective

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Key Elements for Specifying Polished Concrete


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0 25 50 75 100

GlossDOI

DCOFAbrasion

ProfileLife Cycle

Bonded AbrasiveHybridBurnishedSurface Coated

Suggested Applications:ArchitecturalBig Box- New Const.

Small AreasUtilitarian

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Key Terminology for Specifying PC

Determine service type

• Bonded Abrasive Polished Concrete• Architectural finishes• High gloss• Distinct clarity

• Burnished Polished Concrete• Utilitarian• Big box• Light Industrial

• Offices / Lobby• Schools• Heavy traffic areas

• Residential• Restaurants• Showrooms

• Low maintenance• Longest life cycle

• Large areas• Low to medium maintenance

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Determine service type

• Hybrid Polished Concrete• Utilitarian• Big box• Light Industrial

• Surface Coated Concrete• Small areas• Special use (chemical resistance)• Low budget

• Large areas• Low to medium maintenance

• Stairs• Low Traffic areas• High maintenance

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Concrete Requirements:• Minimum strength 4000 psi• Minimum overall floor flatness (ff) 50• Minimum local floor flatness (ff) 35• Maximum fly ash 25%• No slag content• Minimal admixtures (us only as a necessity)• Use of highway screed / bump cut• Use of pans prior to finishing blades• Hard steel troweled...but do not over trowel

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Specify Classification: Texture Appearance• Class A - Cream Finish (very little sand and/or aggregate exposure)• Class B - Fine Aggregate (expose sand and tips of aggregate)• Class C - Medium Aggregate (expose small to medium aggregate)• Class D - Large Aggregate (expose breast of large aggregate)

Specify Level: Glossy Finish • Level 1 - Ground - Low Gloss (no visible sheen or clarity)• Level 2 - Honed - Satin Gloss (minimal sheen with no clarity)• Level 3 - Semi Polished - High Gloss (high sheen with distinct clarity)• Level 4 - Highly Polished - Very High Gloss (high sheen with very

distinct clarity)

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Demand Quality Craftsmanship and Knowledge !

from the only non profit, non biased trade association

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Thank You!Your time and attention are greatly

appreciated...

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Bonded abrasive polished concrete - PaintSquare

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