Rough Concrete Polished Floor Construction Process

In recent years, the construction technology of rough concrete polished floor has become increasingly popular, especially in industrial plants, warehouses, parking lots and other areas with high traffic. This floor solution has many advantages, including high strength, wear resistance, dust resistance, short construction period and low cost. These characteristics make it suitable for a variety of applications and usage scenarios. This article will explore the key points of the construction technology of rough concrete polished floor.

Pre-Construction Preparation

1. Basic treatment

Substrate preparation is a critical step in ensuring the quality and longevity of your polished floor. The following steps should be taken:

• Thorough cleaning: The base concrete must be thoroughly cleaned to remove any scum, oil, debris or other surface contaminants. This cleaning process is essential to forming a strong bond between the concrete and the finish material.
• Repair cracks and uneven areas: Check the concrete surface for cracks or uneven sections. Use specialized patching materials to fill these flaws and level the surface. Properly addressing these issues can prevent future problems and ensure a smooth, even surface.

2. Material preparation

Before starting construction, the necessary materials and equipment must be gathered:

• Diamond grinding disc: You need to prepare diamond grinding discs of various mesh sizes, including 30#, 50#, 100#, 200#, 400#, 800#, 1500# and 3000#. Each mesh size has a specific purpose in the grinding and polishing process, which can gradually refine the surface.
• Concrete sealer: This hardener is essential for improving the durability and appearance of your polished floors. It helps seal the concrete and protects against stains and wear.
• Professional grinding machinery: Equipment such as planetary grinders are essential for effectively grinding and polishing concrete surfaces. These machines provide the necessary power and precision to achieve a high-quality finish.
• Dust collection equipment: To maintain a clean working environment and protect the health of workers, dust collection equipment should be used to capture the fine particles generated during the grinding process.
• Protective materials: Ensure all necessary protective materials such as safety goggles, gloves and dust masks to protect the safety of workers during construction.

Construction Process

1. Coarse grinding

The first step in the construction process is rough grinding, using diamond grinding discs ranging from 30# to 100#. The main purpose of this stage is to remove the mud layer on the surface of the concrete and expose the uniform aggregate underneath.

Key technologies:

Cross sanding: Use the “cross sanding” method, which alternates the direction of the sander to ensure an even sanding of the entire surface. This technique helps to avoid uneven wear and ensures a consistent finish.

2. Intermediate grinding

After the rough grinding stage, the medium grinding is carried out using a grinding wheel with a grit size between 100# and 400#. The focus of this stage is to improve the flatness and smoothness of the floor.

Important note:

• Dust removal: After each grinding wheel change, clean the dust on the floor thoroughly to maintain a clean working environment.
• Grinding direction: Change the grinding direction to 45° from the previous grinding direction. This will help to achieve a smoother surface.
• Constant speed: Keep the grinder moving at a constant speed to prevent local over-grinding, which would result in an uneven surface.

3. Fine grinding

Fine grinding is performed using a 400# to 1500# grinding wheel. This stage is critical because it determines the final appearance of the floor.

Key points:

• Dry surface: Before you start fine grinding, make sure the floor is completely dry. Moisture will affect the grinding effect and the final result.
• Finer grinding process: Use finer grinding technology to obtain a smooth surface.
• Vacuum thoroughly: Vacuum the floor thoroughly after each sanding to remove dust and debris that will affect the quality of subsequent sanding.

4. Polishing

Once the grinding reaches 1500# grit, you can start mechanical polishing. This step requires the use of a 3000# resin grinding disc and polishing fluid to give the floor a mirror-like effect.

Polishing tips:

• Make sure the polish is evenly distributed to achieve a consistent shine.
• Maintain a steady speed while polishing to avoid uneven spots.

5. Curing

After polishing, a concrete sealer and curing agent must be applied. This curing agent can enhance the performance of the floor, including:

• Increased hardness: Floor hardness can be increased by 30% to 50%.
• Abrasion resistance: The hardener increases the floor’s ability to resist wear and tear.
• Dust repellent: It helps reduce dust accumulation on surfaces.
• Penetration resistance: The hardener protects the floor from moisture and stains.

Curing application instructions:

• Apply the hardener evenly over the surface to ensure even protection.
• Keep the floor wet for 1-2 hours after application to allow the curing agent to penetrate effectively.
• Avoid placing heavy objects on the floor for at least 24 hours to prevent damage to the newly cured surface.

Quality Control Points

1. Flatness control

Maintaining the flatness of the concrete surface is essential to achieving a polished floor that meets industry standards.

• Measuring tools: A 2-meter ruler should be used to check flatness throughout the construction process. The deviation should not exceed 2mm to ensure a flat surface.
• Laser screed: For larger projects, a laser screed is recommended for more precise control. This tool can help identify any uneven areas that need to be addressed before further grinding and polishing.

2. Intensity control

The strength of the base concrete is a key factor in the overall durability of your polished floor.

Concrete grade: The strength of the base concrete should be at least C25, preferably C30. This ensures that the floor can withstand the stress of heavy traffic and equipment without damage.

3. Environmental control

The construction environment plays an important role in the maintenance and finishing of concrete.

• Temperature and humidity: The ambient temperature should be maintained between 5°C and 35°C, and the relative humidity should not exceed 80%. High humidity will affect the curing process and the final effect of the floor.
• Winter construction: During the colder months, insulation measures should be taken to maintain optimal curing and polishing conditions. This may include the use of heaters or insulation blankets to protect the concrete from freezing temperatures.

Common Problems and Solutions

1. Ground polishing

Main reason:

• Insufficient strength of the base concrete.
• Overgrinding resulting in material removal beyond acceptable limits.
• Insufficient amount of curing agent used.

Solution:

• Re-curing treatment: The application of additional curing agent to enhance the performance of the floor.
• Local reinforcement: Reinforce areas showing signs of grinding or wear.
• Control grinding depth: Monitor and adjust grinding depth to prevent excessive material removal.

2. Uneven gloss

Precautions:

• Consistent grinder speed: Make sure the grinder is moving at a constant speed to get an even surface.
• Replace grinding wheels regularly: Replace grinding wheels regularly to maintain effectiveness and avoid uneven wear.
• Control grinding time: Monitor the time of each grinding to ensure the uniformity of the polishing process.

3. Solving the problem

Handling method:

• Fine cracks: These cracks can usually be removed with additional grinding, which helps to smooth the surface.
• Larger cracks: For larger cracks, professional repair will be required before polishing can be performed. This may include filling the crack with a suitable material to restore structural integrity.
• Expansion joints: Provide expansion joints where necessary to accommodate movement and prevent future cracking.

Construction Precautions

1. Security protection

Ensuring the safety of operators and the integrity of the construction site is of paramount importance. The following safety measures should be implemented:

• Personal protective equipment: Operators must wear dust masks, goggles, gloves, and other protective gear to protect against dust and debris generated during the grinding and polishing process.
• Machinery inspection: Regular inspection and maintenance of machinery is essential to prevent breakdowns and ensure safe operation. This includes checking grinders, dust collection systems, and any other tools used in the production process.
• Ventilation: The construction site should be well ventilated to minimize dust accumulation and ensure a safe working environment. Adequate air circulation helps reduce the inhalation of fine particles and improves overall air quality.

2. Finished product protection

Once a polished floor has been applied, it is vital to protect the finished product to ensure its longevity and performance:

• Access restrictions: No one is allowed onto the newly polished floor for at least 24 hours to allow the hardener to set properly.
• Avoid impact: Avoid heavy impacts to the floor for at least three days after the application is completed. This precaution will help prevent any potential surface damage.
• Chemical exposure: For the first seven days, avoid contact with acidic and alkaline substances as these can adversely affect the curing process and the integrity of the polished surface.

3. Post-maintenance

To maintain the appearance and functionality of polished floors, regular post-maintenance measures should be followed:

• Daily cleaning: Regular cleaning is essential to keep your floor in good condition. It is recommended to use a neutral detergent to avoid damaging the floor surface.
• Avoid sharp objects: Prevent sharp objects from scratching your floors as this can cause unsightly marks and damage.
• Professional maintenance: Consider scheduling professional maintenance once a year to ensure your floors remain in top condition and address any wear and tear that may have occurred over time.

Economic Benefit Analysis

Rough concrete polished floors offer a variety of economic advantages over traditional epoxy floors, making them an attractive option for many businesses.

1. Cost savings

• Reduce material cost: Rough concrete polished flooring can reduce material costs by approximately 40% compared to epoxy flooring. This significant cost savings is critical for many projects.
• Savings in labor costs: Labor costs can be reduced by approximately 30% due to improved efficiency in the construction process and reduction in extensive finishing work.
• Low maintenance: Rough concrete polished floors require very little maintenance, so the ongoing costs over their lifespan are extremely low.

2. Long service life

Under normal use conditions, the service life of rough concrete polished floors can reach 15 to 20 years, which is 2 to 3 times longer than the service life of traditional floors. The longer service life helps to improve the overall cost-effectiveness of the flooring solution.

3. High comprehensive benefits

The rough concrete polished floor is dust-proof and easy to clean, which significantly improves the use environment and enhances the overall value of the space, making it more attractive to tenants, customers and employees.

In Conclusion

Rough concrete polished floor construction technology provides a practical and efficient solution for a variety of industrial and commercial applications. By following the correct preparation and construction steps, including base preparation, material preparation, and systematic grinding and polishing processes, you can create a high-quality, durable floor that meets the needs of any environment. With its many advantages, this flooring solution is an ideal choice for those who are looking for cost-effective and long-lasting results.