polished concrete specifications and recommendations

POLISHED CONCRETE SPECIFICATIONS AND RECOMMENDATIONS

ISSUE #2, AUGUST 2019

0417 808 680

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www.dsgrinding.com.au

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ii

CONTENTS

POLISHED CONCRETE. . . . . . . . . . . . . 1

BURNISHED FINISH . . . . . . . . . . . . . . 2RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 3

PROCESS . . . . . . . . . . . . . . . . . . . . . . . . 4

INDUSTRIAL FINISH. . . . . . . . . . . . . . 5RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 6

PROCESS . . . . . . . . . . . . . . . . . . . . . . . . 7

FULL AGGREGATE EXPOSURE FINISH . . . . . . 8RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 9

PROCESS . . . . . . . . . . . . . . . . . . . . . . . 10

ADVANTAGES & LIMITATIONS . . . . . . . . . 11

CONTACT . . . . . . . . . . . . . . . . . . 13

0417 808 680 | www.dsgrinding.com.au 1

Mechanical polished concrete (true polished concrete) is a process in which the concrete is treated and worked on in such a way to increase the overall strength and durability of the surface to have maximum abrasion resistance and the longest possible lifespan as a finished surface . This is done with the following methods:

• Correct grinding techniques with appropriate machinery for a mechanical polished concrete system;

• Use of the correct concrete densifiers/hardeners with strict densification techniques;• Use of the correct grout systems and techniques;• Polishing a correctly densified surface to the client’s desired gloss level using the correct

tooling for optimum finish and performance;• Application and use of a high quality penetrative sealer;• Understanding the correct maintenance program/system, the strengths and limitations of

a finished floor and passing this information to the client; and• Having an experienced and well-trained team to complete all of the above .

This brochure will outline the Styles, processes and recommendations for the 3 available types of polished concrete; The Burnished Finish, The Industrial/Architectural Finish and The Full Aggregate Exposure Finish. Matte, Satin or High Gloss sheen levels are available on all styles of polished concrete and can be selected during the finishing stages of the polishing process.

POLISHED CONCRETE


BURNISHED FINISH

This is when the finished floor is to look as though it is a pure and natural concrete surface or ‘untouched’.

There is a common misconception that the concreter simply burnishes the floor, a sealer is applied and it is completed. However, in order to meet the same durability and strength in the surface as all mechanical polished floors, the same densification and sealing processes are required as in all methods of polished concrete. The differences being the grinding stage is done with specialised tools to remove minimal surface stock and the grouting stage is removed from the process. It is important to note that DS Grinding has zero control of the concrete’s flatness and imperfections with this style and is it to be 100% expected to see the flatness and sheen variations in the finished floor. Cracks, divots and imperfections are also expected to be present and highlighted on completion.


BURNISHED FINISH

RECOMMENDATIONSIt is recommended that the concreting contractor call DS Grinding prior to pour to go over the finishing processes so then everyone is on the same page to achieve the optimum outcome.

1. 100mm thick slab .

2. Upgraded mesh to SL 82 or 92 .

3. Minimum of 32mpa concrete with 100% cement content (no reduction of cement for additives such as slags etc.)— no water to be added on site during concrete placement.

4. Bathroom/wet area 40mm stepdowns are recommended to be 100mm inside plan measurements and concrete cut to exact specs post pour to avoid errors .

5. Slab ends meeting garage walls are also recommended to set out 100mm over plan measurements and cut to exact specs post pour to avoid concrete being short next to single leaf garage wall .

6. Any recessed stacker/bifold doors are recommended to be recessed via concrete cutting post pour to avoid dipping .

7. Slab form to be set to actual concrete height by formworker . This is to allow uniform Burnishing by the concreter to all edges . Metal angle is commonly used to top formboards to allow better machine trowel workmanship.

8. Machine panned/trowelled to a Burnished hardened finish making sure trowel machine runs off all edges to create a uniform Burnished slab upon completion.

9. Correct curing of concrete (ponding, watering down, etc.).

10. No pinholes or ripples to be left in the finish of the slab.

11. Avoid the use of oils and staining chemicals/liquids on the slab.

12. The painter is to not leave overspray at doorframes .

13. Use of correct protection methods to slab during construction— NOTE: protection of the slab is of utmost importance during construction as there is no light grout protection layer (adhesive backed/applied floor protection cannot be used).

13. No use of adhesives, tapes, silicone, etc. to the floor at any stage as the chemicals in these products can be absorbed into the concrete and prevent correct penetration of the densifiers and sealer.


BURNISHED FINISH

PROCESS1. Concrete is poured by concrete contractor to specifications given.

I. It is important to note there is no Pregrind Stage to this style .II. Builder is to correctly cure the protect the slab during construction.

2. Builder continues with construction as per normal after application of dedicated floor protection (brick delivery, site clean, full brick up and construction, etc.).

3. 6 weeks from lockup, builder contacts DS Grinding to book in first and final polishing stage to be after lockup and prior to cabinetry installation.

4. After lockup, DS Grinding to arrive to complete all preparation and polishing stages.I. Light grinding of floor to obtain canvas of surface with specialised tooling (zero change

to the flatness levels will occur)— NOTE: no grouting stages are applied to this styled finish.II. Supply and application of densifier stages to the floor.III. Removal of densifier residues.IV. Polish stage 1. (low grit resin polishing pads) – (matt finish)V. Polish stage 2. (medium grit resin polishing pads) – (satin/semi-gloss finish)VI. Polish stage 3. (high grit resin polishing pads) – (high gloss finish)VII. Supply and application of penetrative sealer. (Lithofin MN StainStop)VIII. Removal of penetrative sealer residue with buff pads.

5. DS Grinding hand over floor to builder with protection and maintenance advice.


INDUSTRIAL FINISH

This has a large spectrum of finish options ranging from ‘Minimal Stone Exposure’ to the ‘Hit and Miss’ exposure style.

DS Grinding will use specialised grinding tooling to help control stone exposure while working towards a flatter floor. In most cases, for DS Grinding to achieve a flatter floor overall, some stone exposure may be present in a random effect, i.e. the ‘Salt and Pepper’ style . With ‘minimal stone exposure’, DS Grinding is to find the medium between flatness and minimal exposure . When moving towards a heavier hit and miss style, DS Grinding can grind slightly deeper, which in turn will achieve more of a heavier, random exposure throughout. It is important to note, using the term ‘flat’ and ‘flatness’ does not mean DS Grinding is responsible for levelling the floor to a perfect level of flatness. It means working between the client’s request and the current flatness levels the floor is in at the time of arrival. On another note, if the floor is poured exceptionally flat by the concreter, then DS Grinding can easily achieve any area of the Industrial spectrum throughout .


INDUSTRIAL FINISH




3. Minimum of 32mpa concrete with 100% cement content (no reduction of cement for additives such as slags etc.)— No water to be added on site during concrete placement.




7. Machine panned/trowelled to a hardened finish.


9. No pinholes or ripples to be left in the finish of the slab.


11. The painter is to not leave overspray at doorframes

12. Use of correct protection methods to slab during construction

13. No use of adhesives, tapes, silicone, etc. to the floor at any stage as the chemicals in these products can be absorbed into the concrete and prevent correct penetration of the densifiers and sealer.


INDUSTRIAL FINISH


2. After a 12–21 day curing period, DS Grinding will do the initial ‘pre-grind’ stage and 1st stage of densification.I. Light grinding of floor to obtain control of surface and increase flatness levels. II. Supply and application of 1st densifier.

3. Removal of densifier residue and application of protective grout to entire surface.I. Light grinding of floor to remove densifier residue.II. Supply and application of cement based protective grout to entire surface.

4. Builder continues with construction as per normal (brick delivery, site clean, full brick up and construction, etc.).

5. 6 weeks from lockup, builder contacts DS Grinding to book in final polishing stage to be after lockup and prior to cabinetry installation.

6. After lockup, DS Grinding return to do the final polishing stages.I. Light grinding to remove the protective grout.II. Supply and application of 2nd stage densifier to the floor.III. Removal of 2nd stage densifier residue.IV. Polish stage 1. (low grit resin polishing pads) – (matt finish)V. Polish stage 2. (medium grit resin polishing pads) – (satin/semi-gloss finish)VI. Polish stage 3. (high grit resin polishing pads) – (high gloss finish)VII. Supply and application of penetrative sealer. (Lithofin MN StainStop)VIII. Removal of penetrative sealer residue with buff pads.



This is when the floor is expected to have full and even aggregate exposed throughout the floor.

DS Grinding will use aggressive grinding tools in such a way as to expose the floors aggregate evenly throughout while attempting to keep or improve the concretes flatness overall. After this initial heavy grind, scratch removal techniques, grouting, densification, polishing and sealing processes similar to the above styles are applied to create the finished surface.

FULL AGGREGATE EXPOSUREFINISH





3. Minimum of 32mpa concrete with 100% cement content (no reduction of cement for additives such as slags, etc.)— No water to be added on site.




7. Machine panned/trowelled to a hardened finish. Do not burnish the slab .


9. Minimal pinholes or ripples to be left in the finish of the slab.


11. The painter is to not leave overspray at doorframes

12. Use of correct protection methods to slab during construction

13. No use of adhesives, tapes, silicone etc. to the floor at any stage as the chemicals in these products can be absorbed into the concrete and prevent correct penetration of the densifiers and sealer .

FULL AGGREGATE EXPOSURE FINISH


FULL AGGREGATE EXPOSURE FINISH


2. After a 12–21 day curing period, DS Grinding will do the initial ‘pre-grind’ stage and 1st stage of densificationI. Heavy grinding of floor to even aggregate throughout the surface and increase flatness

levels .II. Light grinding with higher grit metal bonded tooling to remove heavy grinder scratches .III. Supply and application of 1st densifier.

3. Removal of densifier residue and application of protective grout to entire surface.I. Light grinding of floor to remove densifier residue.II. Supply and application of cement based protective grout to entire surface.

4. Builder continues with construction as per normal (brick delivery, site clean, full brick up and construction, etc.).

5. 6 weeks from lockup, builder contacts DS Grinding to book in final polishing stage to be after lockup and prior to cabinetry installation.

6. After lockup, DS Grinding return to do the final polishing stages.I. Light grinding to remove the protective grout — (steps 3.II and 6.I may need repeating

depending on slab) .II. Supply and application of 2nd stage densifier to the floor.III. Removal of 2nd stage densifier residue.IV. Polish stage 1. (low grit resin polishing pads) – (matt finish)V. Polish stage 2. (medium grit resin polishing pads) – (satin/semi-gloss finish)VI. Polish stage 3. (high grit resin polishing pads) – (high gloss finish)VII. Supply and application of penetrative sealer. (Lithofin MN StainStop)VIII. Removal of penetrative sealer residue with buff pads.



As with all flooring options, polished concrete comes with advantages and limitations. Essentially, a mechanical polished floor acts much like a stone floor, but is more durable in strength. It is important to communicate to all clients the realistic pros and cons to any surface, the list below outlines the most common.

ADVANTAGES

ADVANTAGES & LIMITATIONS

High DurabilityPolished concrete flooring is extremely strong and resilient and can withstand the pressure from very heavy foot traffic and equipment. It is very difficult to damage and is nearly impossible to chip or scratch .

Easy MaintenancePolished concrete flooring is relatively easy to maintain. You only need to dust mop or sweep daily to prevent dirt build up . A regular mop weekly to maintain general cleaning is also advised . For deeper cleaning and regular maintenance, there are specialised products available to maintain the surface as it is for many years .

No VOC (Volatile Organic Compounds) Concrete floors do not contain harmful Volatile Organic Compounds (VOC) like some hardwood floors, vinyl carpets and synthetic carpets.

Non-AllergenicConcrete floors are an allergy friendly option, as they don’t harbour allergens and are easy to clean.

Natural CharacteristicsBeing a created product, every polished concrete floor is different. Each surface has its own unique characteristics that make it personal to each customer.

Sustainable Flooring AlternativePolished concrete does not require hazardous coatings or cleaners to maintain the surface.

Seamless DesignPolished concrete surfaces are a seamless flooring solution with no grouting joins or piece joins like tiles or timber.


LIMITATIONS

Hard FlooringLike tiles, polished concrete is a hard surface underfoot, this is something to be considered when installing in an area in which you are standing for exceptionally long periods of time.

Cold UnderfootPolished concrete is no more cold underfoot then tiles or natural stone flooring. However, the customer needs to be aware that like tiles and stone, polished concrete does not retain heat like timber.

Chemical ResistanceMuch like all stone flooring, polished concrete is resistant to many things, but acidic and alkaline materials can damage the surface . Spills need to be cleaned up as soon as possible to avoid etching .

CrackingLike it or not, even expertly installed concrete may develop small cracks. That’s because the large expanse of a slab must endure changes in temperature, moisture and settling. Current technology in construction has eliminated many things that used to cause cracking, however sometimes it can still occur. The majority of cracking is fixed during the construction process, those that occur after completion are usually so minute or ‘hairline’ they can barely be seen. Also, to note, the ‘Industrial/Architectural’ and ‘Burnished’ styles of polished concrete, filled cracks are seen as beautiful characteristics with many clients.

ADVANTAGES & LIMITATIONS

DS GRINDING PTY LTD SHOWROOM

Unit 5/27 Caloundra RdClarkson, WA 5030

Open by appointment only

DS GRINDING / LIMECRETE DISPLAY HOME BASE

55 Salvado RdSubiaco WA 6008

Open 7 days

0417 808 680

[email protected]

www.dsgrinding.com.au

HOMEBASE DISPLAY CENTRE, SUBIACO

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