Presented by: W. R. MEADOWS

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The Art of Polishing Concrete

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This program is registered with the 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.

Thank you!

OBJECTIVES

• Overview of Polished Concrete

• The Process

• Features and Benefits of Polished Concrete

WHAT IS POLISHED CONCRETE ?

• Polished Concrete is a practical, decorative and economical floor system for any facility.

• Polished Concrete is becoming one of the fastest growing products to ever hit the flooring industry.

• Polished Concrete is a multi-step mechanical

grinding & polishing process that utilizes industrial diamonds (tooling) & concrete densifier to level, densify, polish & finally seal the floor from within the interior of the floor surface.

WHERE CAN IT BE USED ?

Recommended for use wherever a dense, wear resistant, architectural pleasing low maintenance floor is desired.

• Manufacturing • Institutional Facilities

• Commercial • Residential

• Warehouses • Convention Centers

• Sports Arenas • Airplane Hangers

• Airport Facilities

ORIGIN OF POLISHED CONCRETE

• Discovered in Tunisia by a granite and marble contractor

• Had utilized wet grinding and polishing on those surfaces and found it successful on concrete

• Mistake made and concrete was polished DRY

• Contractor using equipment from Scandinavia

• Brought to US in early ’90’s

THE EQUIPMENT

THE EQUIPMENT

Diamond Grinding Segments (Metal Bonds)

Diamond Polishing Pads (Resin Bonds)

THE PROCESS

• Ensure floor is clean and dry

• Concrete must be a minimum of 28 days old

• Minimum compressive strength of concrete should be 3,500 psi (24 MPa)

• Dry process – no water added during grinding or polishing

• Certified applicators/contractors

Step 1- 80 Grit Metal Bond Grinding Segment

Step 2- 150 Grit Metal Bond Grinding Segment

Step 3 – Concrete Densifier application

CONCRETE DENSIFIER – WHY ?

• Silicate technology – Hydration of concrete produces calcium hydroxide

(free lime)– Chemically coverts the free lime to calcium silicate

hydrate (CSH) producing a dense surface

• To protect the integrity of the surface• Does not allow the floor to erode, micro-pit or

scratch• Maintains the light reflectivity and shine

Step 4 – 100 Grit Diamond Resin Polishing

Step 5 – 200 Grit Diamond Resin Polishing

Step 6 – 400 Grit Diamond Resin Polishing

Step 7 – 800 Grit Diamond Resin Polishing

Step 8 – 1500 Grit Diamond Resin Polishing

Step 9 – 3000 Grit Diamond Resin Polishing

SEALING / PROTECTION

• Cut down version of densifier

• Silane Siloxane mix

• Thin Clear Epoxy

• Silicone impregnators

• Specifically designed proprietary enhancers

TYPES OF FINISHES

• 800 GRIT: SATIN FINISH THAT WILL REFLECT IMAGES FROM SIDE LIGHTING.

• 1500 GRIT: SEMI-GLOSS FINISH THAT WILL REFLECT OVERHEAD AND SIDE IMAGES FROM 35-45 FEET WITH INCREASED LIGHT REFLECTIVITY.

• 3000 GRIT: HIGH-GLOSS FINISH THAT WILL LOOK WET AND SHOW MIRROR LIKE REFLECTIONS OF SIDE AND OVERHEAD IMAGES.

800 GritSatin Finish

1500 GritSemi-Gloss Finish

3000 GritHigh Gloss Finish

TYPES OF FINISHES

BENEFITS OF POLISHING

• Elimination of Dusting

– Due to free lime (efflorescence)– Vapor drive from below forces free lime to

surface– Can cause adhesive and specialty floor

failures

BENEFITS OF POLISHING

• Stain Resistance

– Reduces the porosity of the floor in conjunction with densifier

– Densification process is a chemical reaction, stain resistance not immediate

– Slows down penetration of water, oil and other contaminants

BENEFITS OF POLISHING

• Restoration of Older Floors

– Rain damage, spalling, pitting, delamination, floor failures

– Removal of top surface and harden the concrete below

– Deteriorated concrete can be strengthened– Impact and abrasion resistance of the

concrete can be increased

BENEFITS OF POLISHING

• Better Lighting

– Reflectivity of the floor– Can reduce lighting costs

BENEFITS OF POLISHING

• Slip Resistance

– Measurement of coefficient of friction and

slip resistance – Exceeds OSHA standards for floors – Exceeds ADA (Americans with Disabilities

Act)– Higher degree of polish is not directly

related to slip resistance

BENEFITS OF POLISHING

• Less Maintenance

– Reduced penetration of contaminants, remain on surface

– Tire marking significantly reduced– No sealing, waxing or stripping of floor

required– No aggressive scrubbing required

BENEFITS OF POLISHING

• Reduced Tire Wear

– Smoother concrete surface can significantly reduce tire wear

BENEFITS OF POLISHING

• Timing of Installation

– Applied after 28 days – no extended time frames between finishing and applying as with specialty coatings

– Non-toxic – can be applied while building is still occupied

– Densifier used in process – approvals through CFIA for use in food handling facilities

BENEFITS OF POLISHING

• Cost Effective

– Relatively inexpensive application costs– Low maintenance costs– One time application – no replacement

costs as with specialty flooring systems

Cost Comparison of Various Flooring Treatments

 Vinyl SheetFlooring* Carpet*

Vinyl compositeTile*

EpoxyTerrazzo*

Epoxy Coating

PolishedConcrete

             

Cost / square foot Installed $2.72 $1.93 $1.23 $9.10 $4.00 $5.00

Annual Maintenance Cost / sq ft $1.39 $1.53 $1.47 $0.46 $0.50 $0.50

Replacement Cost $3.43 $2.24 $1.60 $0.00 $7.00 $0.00

Frequency of Replacement (years) 9 10 15 20+ 6 20+

20 Year Cost $37.38 $39.39 $34.06 $18.30 $24.29 $15.00

Annual Cost / square foot $1.87 $1.97 $1.70 $0.92 $1.21 $0.75

             

20 year cost for 10,000 square ft. $373,800 $393,900 $340,600 $183,000 $242,900 $150,000

*information taken from commercial flooring life cycle cost analysis as provided by The National Terrazzo and Mosaic Association. The 20 year cost includes initial cost, replacement and maintenance costs

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

$400,000

$450,000

1

Vinyl Sheet

Carpet

VCT

Epoxy Terrazzo

Epoxy Coating

Polished Concrete

Cost Comparison of Various Flooring Treatments

BENEFITS OF POLISHING

• Long Lasting

– One time application– Minimal maintenance required to preserve

the appearance of the floor

• Polished Concrete is developed to be a part of your sustainable design.

• Meets low emissions – no VOC• Virtually dust-free process• Increases ambient light – saves energy• Local manufacturing of materials• High Performance System• Meets ADA/OSHA/CFIA requirements• Earn credits towards LEED

SUSTAINABLE DESIGN

LEED

• Assist with LEED credits/points

• Areas:

• MR (Materials & Resources)

• IEQ (Indoor Environmental Quality)

LEED

• How does it assist with LEED credits?• This process:

– Reduces the amount of construction waste– Reduces the cost of building maintenance– Reduces the cost of operation– Reduces the amount of construction materials– Preserves the recyclability of concrete– Reduces airborne dust particulates– Safe for the contractor and personnel– Does not off gas– Contains no VOC’s– Extremely long-lasting

Thank you! Questions?

This concludes the credit portion of the program for The American Institute of Architects Continuing Education System

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