Mastering Concrete Floor Construction: Precise Techniques

The construction of concrete floors incorporates meticulous techniques and carefully designed steps designed to produce impeccable results. From the initial polishing of the base surface to the judicious application of high-penetrating hardeners and the delicate craftsmanship of grinding and polishing, each stage is an integral part of creating a strong and durable foundation. In this article, we provide a comprehensive exploration of the construction steps and professional methods employed, revealing the artistry and precision inherent in concrete floor slab construction techniques.

Polished base: Injecting elegance and precision

When polishing the base surface, first use a heavy-duty grinder equipped with a 50# diamond grinding disc to carefully polish the surface. Use the “vertical and horizontal” method to ensure that the base surface is polished more than twice to a thickness of about 3-5mm to eliminate surface floating slurry. Then remove the dust layer and polish the base surface with a 50# resin bond grinding wheel until uniform aggregate is exposed. Once the polishing process is complete, remove any remaining dust and clean the floor thoroughly with water. Use a vacuum cleaner to remove dirt effectively and ensure the surface is thoroughly dry. It is worth noting that both wet and dry grinding methods can be used to accomplish this task, providing flexibility and adaptability to the polishing process.

Using high-penetrating hardeners (first time): Strength and durability enhancement

The use of high-penetrating hardeners plays a vital role when it comes to maintaining and preserving concrete floors. This process not only increases the durability and longevity of the flooring but also ensures a smooth and beautiful surface. Therefore, you must follow specific guidelines when using a hardener for the first time to achieve the best results.

After the cleaned floor has had the recommended drying time of 1-2 hours, it is time to prepare and apply the high-penetrating hardener. The first step is to dilute the curing agent stock solution with water in the specified proportion. Mixing the solution thoroughly ensures consistent application and penetration into the floor. After the solution is prepared, it should be poured evenly on the ground. Allowing the clear seal hardener to flow and penetrate freely is critical for even coverage and effective sealing. To further ensure even penetration throughout the floor, lightly scrape the surface with a trowel while pouring. This step ensures that the hardener reaches and protects every part of the floor. The dosage of the hardener formulation is an important consideration and the recommended dosage is approximately 0.2 kg per square meter. Proper measurement and application of hardener plays an important role in achieving the desired protective and aesthetic results. In addition to the application process, specific requirements should be followed to ensure the effectiveness of the curing agent. Circulating moisture 30 minutes before application is critical as it creates the best environment for the curing process. In addition, the reaction time of the curing agent should not be less than 10 hours to ensure complete penetration and sealing of the floor.

Polishing the base surface: paving the way to perfection

• Equipment and Materials: When starting the base surface grinding process, it is crucial to use a heavy-duty grinder equipped with a 100# or 200# resin bond diamond grinding wheel. Resin-bonded diamond grinding wheels are specifically designed to provide efficient, smooth grinding with consistent results.
• Method: Adopt the “horizontal and vertical cross” method. This method grinds the base surface in both horizontal and vertical directions to ensure uniform grinding. The cross pattern allows for precise leveling and removal of imperfections, resulting in a superior base surface.
• More than 2 times: It is recommended to polish the base surface more than twice in each direction to ensure thorough and comprehensive polishing. This repetitive process is essential to achieve the desired smoothness and uniformity, especially when working with concrete or stone surfaces.
• Grinding thickness: Maintain a grinding thickness of approximately 1-2mm to effectively remove surface irregularities and defects while avoiding excessive material removal. This controlled grinding thickness ensures accuracy and minimizes the risk of over-grinding or damaging the base surface.
• Cleaning up after grinding: Sweep away grinding dust with a broom or industrial sweeper to eliminate loose particles and debris from the surface. Clean the floor thoroughly with water to remove dust and residue left over from the grinding process. Use a vacuum cleaner to effectively remove dirt or residual debris from the base surface. The vacuuming process further improves the cleanliness and prepares the surface for subsequent construction, coating, or finishing applications.

High penetration hardener application (second): Strengthening the foundation 

• Surface treatment: Make sure the floor is thoroughly clean and dry for 1-2 hours. Any existing coatings, sealants, or contaminants should be removed to promote optimal penetration of the curing agent.
• Dilution of hardener solution: Dilute the hardener solution with water in the specified proportions according to the manufacturer’s instructions. Mix the solution thoroughly to obtain a homogeneous mixture, ensuring an even distribution of active ingredients.
• Application of curing agent: Pour the diluted hardener solution onto the floor, ensuring even coverage. Allows the solution to flow freely and penetrate into the substrate, promoting deep sealing and curing. At the same time, gently scrape the surface with the trowel to help the curing agent penetrate evenly throughout the floor.
• Dosage and Coverage: The recommended dosage of curing agent is about 0.1kg/㎡. Adhering to the prescribed dosage ensures proper coverage and performance of the hardener.
• Resolve uneven local effects: If uneven localized results are observed during the application, adjustments may be necessary. This can include increasing the number of grinds on the affected area to promote better adhesion and penetration.

Additionally, the amount of hardener material used in these areas can be increased as needed to achieve uniform results.

Fine grinding and polishing

• Fine grinding: Use a heavy-duty grinder equipped with a 400# to 1500# diamond resin pad to grind the base surface. Use the “vertical and horizontal” method to polish the base surface more than twice to ensure comprehensive and even coverage. Maintain a grinding thickness of approximately 0.5 mm to achieve the desired smoothness and uniformity.
• Clean: Remove all dust and debris from the grinding process to ensure a clean surface for subsequent steps. Thoroughly clean the floor surface with water to remove any remaining dust, residue, or contaminants. Use a vacuum cleaner to further remove any remaining dust or debris, ensuring a pristine surface for subsequent treatments.
• Slurry removal and drying: After cleaning, use appropriate cleaning methods to remove any slurry produced during the grinding process so that the surface is free of any residue. Allow the floor surface to dry thoroughly before any subsequent treatment or application process.

Spray maintenance brightener

• Prepare maintenance polish: Make sure maintenance polish is thoroughly mixed and prepared according to the manufacturer’s instructions. Use appropriate safety equipment, such as gloves and safety glasses, when handling and preparing polish. Use a special sprayer: Fill the dedicated sprayer with the prepared maintenance polish. Adjust the sprayer for an even, fine spray pattern to ensure even coverage of clean floors.
• Use maintenance polish: Spray the maintenance brightener evenly on the clean floor, keeping the dosage at about 0.03-0.05kg/㎡. Ensures full coverage without oversaturating or pooling the polish.
• Natural drying time: Allow the applied maintenance polish to dry naturally, usually about 5-8 hours. Avoid foot traffic or other disturbances during the drying period to allow the whitener to set and provide optimal results.

Precision grinding and polishing

Install the 3000# resin polishing pad onto the grinder. Sand the surface using a “cross-over” pattern to ensure even coverage. Cycle the grinding process more than 2 times to achieve ideal smoothness and precision. If you are using a special polishing machine with a polishing pad, attach the pad to the machine. Use the “vertical and horizontal” method to cycle more than 2 times to ensure that the surface is polished thoroughly and evenly. Use appropriate dust removal equipment or methods to promptly remove dust generated during the grinding and polishing process. This will help maintain a clean working environment and prevent dust from interfering with the accuracy of grinding and polishing.