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Polished Concrete an in Depth Design to Understanding the Process for Better Design and Implementation 1 Polished Concrete An In Depth Design to Understanding the Process for Better Design and Implementation 1- Friday, December 7, 12 Copyright Material This presentation is protected by U.S. and International Copyright laws. Reproduction and/or use is strictly prohibited. Concrete Polishing Association of America 2012 © 1- Friday, December 7, 12 ConcreteConcrete PolishingPolishing AssociationAssociation - IntroductionIntroduction 1- Friday, December 7, 12 Board of Directors Chemical Manufacturers Greg Schweitz L&M Chemical Company Scott Metzger Metzger / McGuire Joe Reardon Prosoco Equipment Manufacturers Eric Gallup Substrate Technology Marcus Turek SASE Company Stephen Spengler Aztec Products 1- Friday, December 7, 12 Dye / Stain Manufacturers • Carl Cabot American Decorative Concrete Abrasive Manufacturer • Jeff Tchakarov Diamond Tool Supply, Inc. Architectural Representative • Walter Scarborough Hall / Building Information President-CSI Dallas Chapter 1- Friday, December 7, 12 Board of Directors- Contractor Members • Roy Bowman Concrete Visions Inc. (Chairman) • Leonard Hartford Carolina Concrete Floor Polishing (Co-Chair) • Shawn Halverson Surfacing Solutions (Secretary) • Shawn Weaver Concrete Floor Systems (Treasurer) • Scott Truax Middle Georgia Concrete • John Jones Budget Maintenance • Mike Payne Mike Payne & Associates • Leonard Hartford Carolina Concrete Floor Polishing • John Wucinich Finial Finish • Tim Burgess Burgess Concrete 1- Friday, December 7, 12 Over 400 contractors throughout • Alberta • Saudi Arabia • USA • Trinidad • Russia • Ontario • Virgin Islands • Portugal • Colombia • Puerto Rico • Singapore • Thailand • Saskatchewan • Mexico • British Columbia • Australia 1- Friday, December 7, 12 • Developing Industry Standards for Polished Concrete • Defining Procedures and Standards for Contractors • Defining Industry Terminology and Definitions • Assisting General Contractors, Architects, and Owners in the selection of quality applicators • Bringing Craftsmanship and Professionalism to the Industry through contractor training, evaluations, and accreditations 1- Friday, December 7, 12 BBenefitsenefits of PPolishedolished CConcreteoncrete 1- Friday, December 7, 12 Permanent Flooring Solution Performance and appearance will retain greater consistency throughout the life of the surface because, unlike other finishes that rely on topical coatings (surface coated concrete), the concrete polishing process exposes and enhances the strength and durability inherent to the concrete. The result is a beautiful, durable, and efficient surface which eliminated the need for carpet, tile, or coatings that require expensive replacement, maintenance and harsh cleaning chemicals. Low Maintenance Without superficial coatings, concrete polishing leaves you with a product that does not peel, chip or flake over time, making regular maintenance simple while saving time and money. 1- Friday, December 7, 12 Energy Reduction Polishing Concrete to a high gloss (Level 3-4) increases the efficiency of installed lighting due to extremely high DOI (distinction of image). Polished Concrete has the advantage of being able to utilize the natural thermal mass of concrete, allowing for more efficient heating and cooling leading to a smaller carbon footprint. Polished Concrete has the advantage of low maintenance, eliminating the cost of Energy to power cleaning equipment • Chemicals • Labor • Downtime • Periodic replacement / restoration 1- Friday, December 7, 12 Abrasion Resistant Polishing Concrete has an increased abrasion resistance due to: Refinement - the bonded abrasive polishing process refines the concrete surface on a microscopic level to minimize the peaks and valleys which decreases the chances of scratches, wear patterns, and trapping debris. This increases the abrasion resistance by approximately 6%. Densifier - Silicate densifiers (lithium, potassium, sodium, magnesium) react with the calcium hydroxide within the concrete to create a crystalline structure known as calcium silicate hydrate. This chemical reaction increases the abrasion resistance of the wear surface by approximately 20%. Introduction of pozzolans, such as fly ash or fumed silica (amorphous / colloidal), also increase the density and abrasion resistance of concrete. 1- Friday, December 7, 12 Life Cycle Cost Polished Concrete often is less expensive than other flooring options. Long term value is realized in long term replacement / restoration, maintenance and energy savings. Polished Concrete is not maintenance free as some have promoted. However, the routine maintenance is significantly lower and easier than other flooring options. Maintenance generally requires routine cleaning (auto-scrubber with mild PC cleaning solution) and occasionally buffing with diamond impregnated maintenance pads. Associated costs with stripping, top scrubbing, refinishing, re-coating, and deep cleaning are eliminated. 1- Friday, December 7, 12 Life Cycle Cost Factors that influence routine maintenance schedules and costs are: • Amount and type of traffic • Amount and type of contaminant (soil) • Entrance matting • Maintenance procedures • Guard / Stain protectants 1- Friday, December 7, 12 Life Cycle Cost Vinyl Tile $375,000 $375,000 30 Year Cost $251,667 Coangs $128,333 $275,000 30 Year Cost $5,000 20 years 30 years 10 years 5 years Polished Concrete Less than $150,00 30 Year Cost Polished Concrete Coatings VCT Figures taken from American Terrazzo Associaon and Concrete Construc8on MAgazine. Doe not include ini8al installaon. Includes re-installaon at 10 year intervals for VCT and 5 year intervals for coangs. Polished Concrete periodically maintained and refreshed for $0.50 /square foot or lower, annually. 1- Friday, December 7, 12 Life Cycle Cost Bonded Abrasive Polished Concrete that has been properly installed is more durable and has a longer life cycle before restoration than any other floor covering available. Various flooring materials will look great with first installed. As they begin to wear with service, the appearance slowly degrades even with frequent maintenance. Bonded Abrasive Polished Concrete does not go through this frequent cycle. Bonded Abrasive Polished Concrete is permanent, long lasting, and durable. After a significant duration (often 10-15 years of service) a one to three step Hybrid Polishing Process is all that is required to restore the original appearance. 1- Friday, December 7, 12 Functionality Bonded Abrasive Polished Concrete: • Allows for vapor transmission (dyes are MVE sensitive) • Concrete dusting is eliminated 100% • Increased impact resistance • Resist tire marks (forklift and vehicular traffic) • Refined surface that reduces vibration (less equipment repair) • Little or no down time during installation 1- Friday, December 7, 12 Sustainable Design Bonded Abrasive Polished Concrete: • Has no VOCs • Eliminates the use of harsh cleaning processes-thereby eliminating other high VOC chemicals • Better indoor environmental air quality • Reduces heating and cooling loads • Reduces lighting requirements • Reduces disposal of refuse (carpet, vct, linoleum, etc in landfills) • Overall reduces Environmental Footprint of building construction 1- Friday, December 7, 12 IntroductionIntroduction andand OverviewOverview 1- Friday, December 7, 12 POLISHED CONCRETE The act of changing a concrete floor surface, with or without aggregate exposure, until the desired level of finished gloss is achieved by using one of the listed classifications; Classifications of Polished Concrete Include: • Bonded Abrasive Polished Concrete • Burnished Polished Concrete • Hybrid Polished Concrete 1- Friday, December 7, 12 POLISHED CONCRETE Bonded abrasive polished concrete - The multi-step operation of mechanically grinding, honing, and polishing a concrete floor surface with bonded abrasives to cut a concrete floor surface and to refine each cut to the maximum potential to achieve a specified level of finished gloss as defined by the CPAA. This yields the most durable finish and requires the least maintenance. 1- Friday, December 7, 12 POLISHED CONCRETE Burnished polished concrete - The multi-step operation of mechanical friction-rubbing a concrete floor surface with or without waxes or resins to achieve a specified level of finished gloss as defined by the CPAA. This operation yields a less durable finish and requires more maintenance than bonded abrasive polished concrete. 1- Friday, December 7, 12 POLISHED CONCRETE Hybrid polished concrete - A multi-step operation, using either standard grinding / polishing equipment, lightweight equipment, high speed burnishing equipment, or a combination of, to combine the mechanical grinding, honing, and polishing process with the friction rubbing process by utilizing bonded abrasives, abrasive pads, or a combination of, to achieve the specified level of finished gloss as defined by the CPAA. 1- Friday, December 7, 12 POLISHED CONCRETE Surface coated concrete - Surface coated concrete does not conform to the definition of polished concrete per the CPAA. It is the operation of applying a film forming coating to a concrete floor surface to achieve a specified level of finished gloss. Durability depends on the quality of the chemical coating used, the amount of traffic across the floor, and floor maintenance. 1- Friday, December 7, 12 Suggested Applica?ons: Bonded Abrasive Architectural Hybrid Big Box- New Const. Burnished Ulitarian Surface Coated Small Areas Gloss DOI DCOF Abrasion Profile Life Cycle 0 25 50 75 100 1- Friday, December 7, 12 Equipment,Equipment,
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