Concrete Floor Renovation – Concrete Grinding

Grinding Concrete surface
Grinding Concrete surface

Concrete floors are elegant, especially when it’s smooth and colored. Concrete is hard to maintain, many factors can affect the quality of concrete. In an average of 20 years concrete top surface will begin to crack and fragment. Maintenance of concrete surface is hard mission, where it could paint using epoxy layer. However epoxy look nice, it does not suit outdoor applications because the sun will ruin it. Therefore it will not last for long period and will be expensive solution. On the other hand, grinding concrete top surface is another solution, however it grinds is a hard and sensitive mission. This topic will discuss the process of concrete grinding as FAQs. I got these informations throughout my experience at renovation of a petrol station that has a concrete floor.

FAQs

By grinding the surface it will remove the color?

The concrete color is a powder added to concrete surface during concrete initial sitting. Craftsman distributing color powder by throwing it over the surface. Thickness of colored layer can’t be customized, and it isn’t equal it all areas. Therefore, if concrete defected and cracks are small then it will be easier to grind a thin layer and keep it color. In case of large cracks it has to be grinding until reach concrete gray color. Noted that color layer thickness usually is few millimeters, but could be a few centimeters in some spots. 
Remove concrete floor color

What are the machines used for grinding concrete?

Grinding concrete is about the blades, the blades can install at hand grinder or floor grinder machine. Floor grinder is better because it gives level grinding surface, however floor grinder is hard to reach small area. Hand grinder is suitable for small areas, but it requires a skill worker to smooth and level concrete surface.
Concrete grinding blades came in different sizes, 10” to suite floor grinder and 7”, 5” and 4” fit hand grinding. When blade’s segments number increases it will grind faster, also different segments shapes can give smoothing, leveling or reaching corners. Producers write at the products the differences between them and where to use each.
Concrete grinding machines

How to collect dust during grinding?

Grinding the concrete surface will cause a lot of dust, dust is air pollution that affect the environment. Also the powder on the surface has to be collecting because it will give roughness to the surface. Dust can collect by a vacuum (dry grinding) or by pouring water (Wet grinding) to dissolve the concrete power in order to remove it away from site.
Dust during grinding concrete

What is the difference between wet and dry grinding?

Wet and dry grinding are methods to collect grinding dust. Dry grinding is to collect dust by vacuum, where it requires a special system and accessories for tools. Wet grinding requires fewer machines and installation, it requires water only. However wet grinding requires less installation, water will ruin the blade faster.Also powder and water will contaminate the sewage system, especially when it has a colored powder.

Grinding Concrete will result smooth surface?

Unfortunately, concrete has sand therefore it will not be smooth as top surface or terrazzo tiles. Sand particles are very strong and hard to break, sand used for sanding materials to have rough surfaces. So sorry you will not have a smooth surface.

How can i get a smoother concrete surface?

By adding chemical materials like stains. Stains will make concrete appear as it’s wet, although different products have different glossiness. Stains also protect the concrete surfaces from scratching and reduces absorption to avoid oil and water leakage inside the concrete.
Concrete sealer

Can i paint the grinding surface?

There are anti-scratch paint types, also use outdoor paints to protect it from the sun rays. Some types of epoxy paints has auto level specifications, which will level the surface in order to have it smooth and elegant. Some types of stains have color in it, it will remain translucent and concrete texture will appear in different colors. 

How can i add aluminum profiles to concrete?

This by creating a saw cut in concrete surface in width of few millimeters and few centimeters deep. Then using Sikaflex product to glue aluminum T profile to the groove on concrete surface. Be careful to clean aluminum and the groove from any dust before glue it. Remember that aluminum is installed at the floor, and it’s prone to scratching and unglued from concrete due to movement.

Methods of ceiling marble cladding

Marble ceiling cladding gives the architecture feeling of marble masses, the building appear as a piece of marble. However there are several types to install marble at ceilings, each method has advantages and disadvantages. Through this article we will discuss ceiling cladding methods,then you can make a decision about which method to use.

There are three methods of installing marble at ceilings. A method before casting the slab and two methods after casting the slab, one of them is using mechanical system. We will discuss the mechanical way of installing in another topic.

Before casting slab method

it’s the most common and simplest way of installing. Where marble place on the wooden framework, and it installs a steel inside the marble. Marble adhesive used to connect marble tiles together. This method sounds easy but it doesn’t reach a good result because it may move during concrete casting. Tiles could move, then it is recommended to put a mortar over the marble to enhance the bond and to protect marble adhesive from ruin by sun rays.

A problem facing this method, frameworks surface is hard to get it leveled, and any defect will appear clearly. Solving this problem can be either by chamfer the tiles edges, then it’s hard to notice its not level. Another alternative is to adopt the wood frame level, either by putting an over layer plywood to re-level the surface. For professional it’s recommended to make cladding surface lower than the rest of the slab by 5 cm. Then put sand into this area and arrange marble tiles as its verse tiling, then you can control the level precisely. 

marble cladding for ceilings methods
During working at marble cladding for ceiling, and before installing it rips blocks and steel bars. Gaza 2018
This craftsman, install Travertine tiles for ceiling cladding, using before casting method. He uses small marble pieces to gather tiles at same level by marble adhesive. Gaza, ORIGIN DESIGN, 2019
marble cladding for ceilings defects
marble cladding for ceilings defects, Gaza 2018

After casting slab – by casting method

This method has a better quality than the previous method, but it is not suitable for a large area. By making a new framework underneath the slab and by leaving the thickness of the marble and a space for cement mortar. Then steel wire will connect to the marble tile, after that arrange marble at the framework. Then connecting the marble wires to a steel mesh connecting to the concrete slab, and then it’s ready for concrete casting. We need to cast the concrete from the top, this by opening a 10 cm open at the concrete slab. But be aware to add more water to the concrete and extra cement to have a good concrete suitable for this job. It’s better to open several openings for casting at the slab. Because we need concrete to reach the top and air will get out through them.

After Casting method, Gaza 2018

As much as marble has a brilliant appearance at ceiling but also installing it is not an easy job, and it’s hard to fix and defects after installing.