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WHY A UNIFORM CANVAS IS IMPORTANT FOR POLISHED CONCRETE

October 15, 2019

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Polished concrete floors are attractive and eye-catching. Businesses with smooth, gorgeous flooring stand out in their respective industries. Few people realize, however, that the stunning appearance of a polished floor begins with the slab of concrete. With older and existing concrete floors, you don’t have the luxury of controlling how they were placed, so you polish whatever you are starting with. With new concrete floors, it is different in that you have the opportunity to control and craft the floor you start with well before polishing ever begins. In our industry, this is what we call creating a uniform canvas.



While concrete is imperfect, taking measures to prevent common defects during installation is important for certain aesthetic goals in your polished finish. The common assumption that polishing hides or eliminates concrete defects is a misconception. In fact, polishing an imperfect concrete canvas usually accentuates existing flaws.


The following content explores the process of creating as uniform a canvas as possible by eliminating four common imperfections that can occur when installing new concrete floors.


FOUR COMMON CANVAS DEFECTS

  1. Differential Aggregate Exposure
  2. Surface Finish Density Differences
  3. Saw Cutting
  4. Curing Discoloration or Blemishes


DIFFERENTIAL AGGREGATE EXPOSURE

When the concrete aggregate is exposed at differing depths, differential aggregate exposure occurs. A variety of reasons could affect this, from the process utilized to place the concrete to the chosen pouring method. The following guidelines aid in avoiding differential exposure when laying concrete for polished concrete projects:


Eliminate aggregate stacking. If possible, always place the concrete straight from the truck. When a pump hose is absolutely necessary, keep the hose in motion. Allowing it to rest in a single spot for too long during concrete discharge results in stacking.


Perform uniform consolidation. Don’t leave the vibrator in a single place for an extended period of time, as this visibly divorces the aggregate from the cement paste. In a project’s planning phase, ensure that the vibrators to be used are consistent in size, frequency, vibration time, etc.


Minimize or remove bump cutting. During finishing, bump cutting deposits paste from high spots to low spots, resulting in high spot aggregate being exposed first. Considering utilizing pan floats for flatness before polishing for even exposure.


Lessen walking on slab: Frequent stepping on the concrete brings excess paste to the surface, a visible defect seen during polishing. As a prevention tactic, use a strike-off screeding method that doesn’t require standing on young, malleable concrete.


SURFACE FINISH DENSITY DIFFERENCES

Differences in surface finish densities frequently occur, sometimes only noticeable after polishing. The following tips help eliminate these differences:


Machine and hand finish carefully. Both methods appear differently during polishing. Use a beveled form edge at pour edges and a machine finish over form edges. For concrete slabs poured against walls, utilize a walk-behind machine; employ a ride-on machine close to columns or construction joints.


Avoid burnished finishes. When burnishing is performed, the polished concrete surface will not be uniform.


Check for mortar. Before troweling the concrete, ensure that every troweling machine is free of residual mortar. Fallen mortar under the machine visibly scratches the canvas.


SAW CUTTING

During saw cutting, utilize an early-entry power saw to reduce out-of-joint cracking. Also, a vacuum must be attached to the saw for immediate saw cut residue removal. Residual residue will both discolor and scratch the concrete, ultimately ruining a final polished floor.


As the last layer of protection against scratching caused by remaining debris, adhere a Velcro fastener strip to the skid plate.


CURING

Wet curing your concrete slab is the most recommended method for polished concrete floors. The best covers for holding moisture are fashioned from a poly-backed cellulose material. To prevent discoloration from differential cure during the curing process, a broom or roller should be applied to smooth any wrinkles across the canvas. When curing blankets aren’t applied consistently, or wrinkles across the blanket exist, air exposure is inconsistent across the concrete. Thus, the concrete is allowed to breathe more in certain areas and discoloration occurs.


To further diminish the danger of discoloration, pour enough water below the cure blankets. After removing the cure blankets, clean the concrete canvas surface. Salts will arise from bleed channels and should be scrubbed while in their soluble state. Once hardened, the salts will begin to discolor the canvas.


WHY DOES A UNIFORM CANVAS MATTER?

Eliminating common concrete canvas imperfections is important, because initial blemishes may last forever. Polishing a concrete surface often accentuates flaws. Especially for Class A or Class B exposure, even minimal mistakes may never be removed.


ROYALE CONCRETE

If your project is still in the planning stages, consult your concrete floor finish professionals. Flooring experts will discuss the methods used for slab placement and how these might affect your goals for the final floor finish.


At Royale Concrete, we believe that it is important for you to understand every variable before ever placing your concrete. We provide consultation, technical documents, and expert advice to ensure that every trade is on the same page. Furthermore, we are passionate about your final floor finish. Expert consultation prior to concrete placement ensures that the canvas meets all of your goals. This eliminates frustrations with creating your final floor finish or limiting your options altogether.


Don’t worry if you have already placed your slab. We can still help! You have many, great options regardless of the condition of your floor. Dustin Bartz, from Estes Construction, wrote: “Royale Concrete was able to tackle a challenging project with their skilled team.” Whatever your commercial project, our professional team at Royale Concrete will complete it with excellence. Contact us today to discover every option possible for you!

RESTORING TERRAZZO FLOORS IN OLDER BUILDINGS

May 15, 2023
If you’re looking at your Terrazzo floors and wondering whether it’s worth it to restore them, you’ve come to the right place. We’ll answer this question and look at the reasons why restoring Terrazzo floors could be a good option for your flooring needs. TERRAZZO FLOORS Terrazzo flooring is exceptionally durable, beautiful, and known for its mosaic-like design. While these floors rarely need major restoration, if an old floor has chipping, cracking, or other signs of imperfection, it’s essential that you don’t leave them as-is. Otherwise, more damage can occur. Other issues you might notice include: Scratches Holes Discoloration Stains Thankfully, even these issues are fixable, and your Terrazzo floor can be restored to its former beauty. RESTORING TERRAZZO The first step in restoring Terrazzo floors is to remove any debris or substance that is on top of the flooring surface. This includes wax and sealers formerly used for the floor. Next, if there are any holes, cracks, or missing areas, an aggregate will be crafted to match the pattern of the existing floor. Cracks and holes will then be filled in. Once holes and cracks are filled, polishing begins. This is where the real magic happens. For Terrazzo floors and many other types of concrete flooring, polishing is what makes the floor come to life. Terrazzo concrete flooring can be restored to its former glory even if carpet has been applied over the top, it has glue, wax, or other tacky substances, or it bears holes or cracks. Once restored, Terrazzo floors can be enjoyed for years and look just as beautiful as ever. WHY POLISHING? There are numerous reasons to choose polishing for Terrazzo restoration over waxing. They include: Maintenance Cost Longevity Ease of cleaning After Terrazzo floors have been polished, they are resistant to spills, require minimal upkeep, and will keep their shine for years to come. The low cost of maintenance makes polishing an ideal choice for schools and government buildings. Occasional touch-up polishing will maintain the shine of your floor. However, even with occasional touch-ups, polishing is far more affordable than regular waxing and results in even more significant cost savings. Polished floors keep their shine and, with regular maintenance, rarely need repolishing even in areas of high foot traffic. This makes polishing an obvious choice for the life of your concrete floors. When wax is used, residual wax will typically need to be cleaned, and a yearly coat reapplied and maintained, adding to the overall cost of maintenance and upkeep. When cleaning polished Terrazzo floors, you’ll need minimal supplies. The items your office building or school janitor already has on hand are likely enough to keep your floors clean and shiny for years to come. A dust mop and a wet mop are all you need to keep your polished floors maintained and shiny. A ROYALE TEAM At Royale Concrete , we know Terrazzo concrete, how to restore your flooring, and what type of restoration work is best for your needs. We have been CPC Craftsman Certified by the American Society of Concrete Contractors and proudly hold membership in the American Institute of Architects. We have been given an A+ rating by the Better Business Bureau and strictly adhere to all OSHA safety guidelines. We proudly offer customized solutions that fit your needs and your budget. Our expertly trained team of professional craftsmen are available for any service you need from preparation and polishing to coating and repair work. At Royale Concrete, we take pride in our work and strive to ensure you are satisfied with the finished product. Give us a call today at (888) 568-6001 or fill out our contact form and let’s see how Royale Concrete can help you.

THREE QUESTIONS TO ASK YOUR POLISHING CONTRACTOR

May 12, 2020
If you’re looking to hire a company to provide concrete polishing, it’s essential that you know what to look for before you sign the contract. While there may be numerous companies offering concrete polishing, it’s crucial to hire the most knowledgeable and experienced companies for a top-quality job. Here are three questions to ask any polished concrete contractor before you hire them. ARE YOU CPC CRAFTSMAN CERTIFIED BY THE ASCC? If you’re not familiar with the world of concrete, this might sound like Greek to you. This certification, however, is one of the most important certifications a concrete contractor can receive. The ASCC is the American Society of Concrete Contractors . It’s been in operation since 1964 and is a non-profit association specializing in aiding concrete contractors with: Safety Resources Continuing Education Opportunities Industry Expertise and Best Practices Certification The CPC Craftsman certification is given by the ASCC only after rigorous criteria have been met, including passing official examinations and documenting a minimum of 4,500 hours of concrete polishing experience. This certification tells you that the company you are considering for your job has been through significant testing and certification processes for the task at hand. CAN YOU DEMONSTRATE EXPERIENCE WITH SIMILAR PROJECTS IN SIZE AND SCOPE? After establishing a company’s certification, the next question you want to ask is regarding their work history. To be certified, they’ve had to put in 4,500 hours of concrete polishing work. That doesn’t mean, however, that they’ve ever dealt with the size and scope of work you need. Ask to see before and after pictures of projects they have completed similar to yours. Professional companies should have documented evidence that strongly supports their history and ability to perform concrete polishing jobs for businesses, schools, government offices, and residential needs. If the company you are considering has no documentation of any kind, consider this lack of evidence to be a warning flag and proceed with caution. It’s rare to find professional companies that entirely lack documentation of their hard work. CAN YOU PROVIDE REFERENCES FROM PREVIOUS CUSTOMERS? The best concrete contractors are proud of the work they perform and strive to produce a finished result that customers will rave about. Reviews and references from former customers are the lifeblood of many companies that rely on word of mouth to pass along the quality of their work. Most companies should have a file on hand of customer testimonials regarding the work they’ve completed. After you’ve seen the company’s provided references, check Google, Yelp, and the Better Business Bureau for more reviews. Get opinions from customers who have used the company you’re considering and proceed accordingly. GO AHEAD, ASK US! At Royale Concrete , we are proud to answer these questions. We have been in operation since 2006 and are CPC Craftsman Certified by the ASCC. We have an A+ rating by the Better Business Bureau. We are well-reviewed on Google and Facebook We have completed projects of a wide variety of scope and sizes Our team is made up of hardworking, dedicated professionals that strive to provide our customers with the best solution for their needs and budget. We specialize in commercial concrete polishing, repair work, surface preparation, and coating. If you’d like to see our work , we have a gallery of before and after photos. Our team has completed projects for: Schools Government Offices Gyms Dealerships Showrooms Heavy Equipment Shops We’d love the opportunity to talk with you about your project. Let’s see how we can get your floors looking beautiful. Call us at (888) 568-6001 or fill out our contact form today!

BENEFITS OF POLISHED CONCRETE FOR WAREHOUSES

May 12, 2020
Warehouses receive a lot of wear and tear on their flooring. No matter what kind of business you have, heavy machinery, endless foot traffic, supplies, carts, shelving, and storage containers move across and get stored on top of your flooring. While polished concrete may not be the best for every warehouse, it can considerably benefit warehouses that are able to take advantage of the process. Here are several reasons why polished concrete is great for warehouses. INCREASED SAVINGS When you have your concrete flooring polished, you’ll increase savings in two ways – time and money. Cleaning your polished concrete floor is relatively simple and can be done with supplies you already have on hand. Your facilities maintenance staff can clean with an industrial floor scrubber and you’ll keep your polished floors looking great for years to come. Thanks to the smooth surface of a polished floor, clean up will be much faster, as well. When it comes to cost savings , the process of polishing a concrete floor is up to six times less expensive than VCT or Epoxy coating. Since polished flooring lasts for so long and requires so little in the way of maintenance, you’ll save money in the short and long-run when you have this process done. BETTER DURABILITY Plain concrete is durable; there’s no doubt about that. But by polishing the surface, the floor becomes even more functional. When the entire process is complete, a succession of diamond grit tools will have been used with our industrial grinders, creating a highly refined surface that is tight and dense. Since there is no rough concrete, there is less opportunity for chipping and breaking from machine traffic. Polished concrete is significantly more durable than unpolished and is the reason why many companies with warehouses, distribution centers, and manufacturing plants choose this method. LEVEL PLAYING FIELD As a warehouse floor ages slab curling, heaving, and cracking can cause disruptions to the surface of the floor. Uneven flooring in a warehouse can cause long-term losses in productivity and maintenance costs on ridged fork trucks. Polishing the surface of your concrete floor can cover remedy these functional imperfections, restore productivity, and alleviate any unnecessary stress on your machinery. Long term problems require long term solutions and a simple polishing job will only cover these issues temporarily. Work with a contractor who can diagnose the root cause of the issue first. Control and expansion joints are the common culprit for uneven flooring and must be inspected before moving forward with any warehouse project. Grinding, polishing, repairing and filling the control and expansion joints can alleviate unnecessary pressure on the floor itself, providing long term durability. LONGER LASTING AND SAFE Polished concrete flooring requires very simple maintenance to keep it in the best shape possible and extend its life. While the shine will eventually diminish and need to be touched up, the durability and dustproof nature of your flooring will not. Polished concrete can handle significant weight, foot traffic, and machinery for years to come. After the polishing process is complete, concrete floors are very safe . They meet, and often exceed, ANSI standards for flooring. It may look like glass, but the co–efficient of friction is higher than regular concrete, meaning employees will be less likely to slip and fall. To find out more information on slip resistance, visit the CPC to view industry standard data for different gloss levels. ECO-FRIENDLY Polished concrete is one of the most eco-friendly flooring options available. The polishing process uses the current substrate in your building and makes it stronger, more durable, and much better looking. Even if your floor has experienced significant wear, cracking, or deterioration, the polishing process can revitalize your floor, bring it back to life, and provide a fresh alternative. Polished concrete flooring also provides better lighting in warehouses. Due to the increased shine and reflective nature after polishing, flooring will reflect the lighting from above. This can enable you to use less light and still create just as bright of a work environment, conserving power, and cutting down on your eco-footprint. POLISHED CONCRETE FOR YOUR WAREHOUSE When you hire Royale Concrete , you’ll gain a team of dedicated and experienced craftspeople who are passionate about their trade. Polishing concrete is just not just a job – it’s part science and part art, and we love what we do. Royale Concrete offers a range of services from terrazzo polishing and surface preparation to coating, concrete maintenance, and repair work. Whether you have a residential or commercial flooring need, we strive to deliver the best service you’ll encounter. Our multiple craftsman are CPC Certified by the ASCC, OSHA Certified, and backed by an A+ rating from the BBB. Drop us a note or call us at 888-568-6001 and let’s see if your site is a good fit for polished concrete flooring!
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