Floor Preparation and Polished Concrete Applications for Insulation and Industrial Flooring

Substrate Preparation

Substrate preparation for insulation and industrial flooring involves grinding away the soft laitance layer on the surface of concrete or substrates with equivalent hardness and suitable mechanical properties, as well as removing concrete dust, plaster, paint and similar contaminants subsequently applied to the surface using machines and cutting tools designed for this purpose. This is done in stages to reach the durable zone of the concrete and to prepare a suitable surface that facilitates adhesion of insulation materials, epoxy self-leveling floor materials, acrylic floor materials and similar products. The grinding process creates capillary scratches on the concrete surface. The industrial floor material to be applied fills these scratches and provides maximum adhesion to the concrete substrate. This ensures that the applied floor treatment is healthier and has a longer service life. At the same time, the grinding process significantly reduces trowel marks, tray marks and undulations in the concrete substrate, thereby reducing the consumption rate of the industrial floor products used. Metal grinding cutters (metal diamonds) are used to reach the durable zone of the concrete. These cutters are categorized and manufactured according to the hardness value of the concrete to which application will be made. They are also classified as 20 grit, 30 grit, 60 grit and so on according to the particle values known as diamonds contained within them. These diamonds are selected and used in a manner suitable for the intended application. The machine used for grinding also plays an important role in diamond selection. The appropriate diamonds should be selected according to weight and working method before processing begins.    

Polished Concrete Applications

Polished concrete applications are created in the same way by performing substrate preparation, then applying grinding processes in stages in the durable zone of the concrete, and subsequently continuing with resin-bonded diamonds manufactured specifically for polished concrete applications. Resin-bonded diamonds are classified according to their particle values, such as 50 grit, 100 grit, 200 grit and so on, in the same manner as metal diamonds. The application of resin-bonded diamonds begins after substrate preparation with metal diamonds is complete and polishing is carried out until the resin-bonded diamond value is reached as determined by the desired floor characteristics. For example, 50-100 grit may be sufficient for dust-free flooring, while 200-400 grit level polishing may be adequate for semi-polished flooring application. As these values may vary depending on the characteristics of the substrate, it is difficult to provide precise examples; however, generally the contractor and client agree on the values to be applied on sample work and satisfaction is ensured for both parties. Another product used in polished concrete applications is liquid surface hardeners. The most widely used product in this category is Lithium Silicate. When liquid surface hardeners are applied in sufficient quantities and in the proper manner, they penetrate the concrete surface to prevent dusting and harden the concrete, providing longer-lasting and healthier performance. In addition to these, liquid surface polishes are also manufactured for fully polished flooring. Polished concrete applications can generally vary according to every budget and preference. As can be understood, the flooring is created by processing the raw concrete and is absolutely not a surface coating application. For this reason, compared to other applications, it has many advantages such as ease of application, cost-effectiveness, practicality and long service life. Machine selection for these applications is also of great importance in terms of application and labor. Various machines with different mechanisms and sizes are available for all types of surface work. The main variables in machine selection can be broadly classified as application area, concrete type, concrete placement method and intended application. It is recommended that these selections be made by experienced and expert personnel. As Asferah Makine, we work to deliver machines and equipment suitable for every type of industrial flooring work and purpose to our customers. All machines and equipment whose designs are made by us are domestic, and all components have been specially designed and engineered so that we do not leave you halfway. Asferah Makine will provide you with exceptional service and after-sales support and ensure your satisfaction.   Sedat Avcı Mechanical Engineer Asferah Makine İml. İnş. İth. İhr. San. ve Tic. Ltd. Şti.