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One of many reasons polished concrete toppings are popular as a finished floor system for both damaged floors and new construction is customers want polished concrete without all the flaws showing up in the finished floor. Placing and polishing a concrete overlay requires a great deal of attention and more coordination than polishing an existing slab. Here are a few tips when taking on an overlay-polishing job.
Thin coatings that can be polished work wonders on floors new and old. But applying them right takes know-how.
Concrete Visions uses mirrored-glass aggregate to create a polished concrete overlay that mimics a winter wonder every day of the year. Product used was TRU Self-Leveling.
The decorative options available with a polishable cementitious overlay turns a damaged, ugly floor into a completely different surface. The overlay offers an easy solution to make the floor designable, for both decorative and functional effects.
Decorative polished concrete provides lower maintenance costs, is better looking, more attractive and uses environmentally friendly material. Product used was TRU Self-Leveling.
Calcium sulfoaluminate (CSA) cement products have provided architects and contractors with the ability to produce beautiful flat, polished floors in a fraction of the time, with considerably less expense than using portland-cement based concrete and constructing entirely new floors.
The extensive amount of repairs required to meet JCP’s expectations will strengthen the industry and keep expectations high when it comes to polished concrete. Product used was TRU Self-Leveling.
Waikiki Trade Center was transformed into an upscale, 230-room hotel by Swinerton Builders Hawaii. The hotel includes street-level retail space and Nordstrom Rack. Nordstrom specified Rapid Set® Products for the overlay, which included LevelFlor, TXP Epoxy Primer, and TRU Self-Leveling.
The owner requested a decorative design be added to the polished concrete floor surface. The chosen design was a display of roses with angel wings embracing the long stems. The mural was scored into the floor and the 3-D effect was brought to life with varying dyes and pigments. Product used was TRU Self-Leveling.
Three projects illustrate Calcium Sulfoaluminate (CSA) cement-based products are highly effective materials to use when needing to meet aggressive timetables, reduce costs and achieve high quality results. These materials have far more rapid set times than portland cement, and allow for a range of architectural touches and decorative finishes, including colored and polished overlays. Product used is TRU Self-Leveling.
Five international projects show how construction products play a supporting role in industries where new technology rollouts, tight timelines, and sustainable design are the new normal. Products used include Cement All, Concrete Mix, Rapid Set Cement, SET Control, and TRU Self-Leveling.
12,000 sq ft of floors in common spaces, corridors, and the lobby were polished and decorated with a colorful block pattern. By the project’s end, the contractors and design team were able to come under budget with beautiful results and students at the new elementary school will be able to enjoy a creative, collaborative learning environment. Products used include TRU Self-Leveling, TRU Self-Leveling Spiked Roller, and TXP Fast Epoxy Primer.
Tri-State Underlayments/Franz Floors only had four days to restore 1,200 sq ft of the existing flooring before interior framing began. For this reason, the contractor chose to use Rapid Set cement products to install the flooring, because they set quickly to produce 3,000 psi in one hour and full strength of 8,000 psi in one day. Products used include Concrete Mix, FLOW Control, SET Control, TXP Primer, TRU Self-Leveling.
By using fast-setting materials to speed installation time and choosing colored glass as the embedded aggregates instead of pricier materials, like marble chips, D.J. Rosetti was able to provide the owner with a strong, attractive and budget-friendly terrazzo flooring option. Products used include TRU Self-Leveling, TRU Self-Leveling Spiked Roller, and TXP Fast Epoxy Primer.
The project’s scope included 9,000 square feet of concrete overlay and resurfacing both indoors and outdoors for walkways, hallways and more. A non-porous, cementitious surface was required, and the crew was working against a tight timeframe to completion. Products used include Acrylic Primer and TRU Self-Leveling.
To ensure decorative overlayments achieve performance and aesthetic expectations, compressive, tensile and flexural strengths must be evaluated as a whole. Together, they provide a more comprehensive analysis of overall performance. This approach help architects and specifiers meet and exceed performance and aesthetic expectations in polished overlay designs.
Contractors often face challenges when asked to produce a uniform appearance in a polished concrete overlay. To achieve consistency in each project, here are the three necessary steps to take before grinding and polishing.
The University of Cincinnati renovated the 1819 Innovation Hub. LevelFlor, TRU PC, and TRU Self-Leveling were used to renovate the 40,000 sq ft floor.
The foundation of the main lobby in this office space was leveled with LevelFlor, then TXP Fast Epoxy Primer and TRU Self-Leveling were used to create the polished concrete overlay.
Aloft Tampa Downtown is a hip, high-end luxury hotel with lustrous polished concrete floors. Acrylic Primer and LevelFlor were used as the underlayment. TXP Fast Epoxy Primer and TRU Self-Leveling were used to create the polished concrete overlay.
Amazon's corporate office wanted to upgrade the elevator landings of its multi-floor office space. At each landing, TXP Epoxy Primer and TRU Self-Leveling were used. As a final decorative and functional touch, the corresponding floor numbers were stenciled on each landing.
Blue C Sushi wanted an integrally colored black polished concrete floor in their new restaurant. Cement All was used to patch the substrate before performing surface prep. TXP Fast Epoxy Primer was used to prevent pinholes and create a strong adhesive grip for the topping. Then TRU Self-Leveling with black integral color was placed at 3/8 inch thick.
Cement All was used to patch the substrate before performing surface prep. To prevent pinholes and create a strong adhesive grip for the topping, TXP Fast Epoxy Primer was used. TRU Self-Leveling with integral coloring was used as the topping. To make sure the TRU did not set too fast in the heat, SET Control was added to the mix.
Build-out of the new Burlington Coat Factory included replacing two levels of uneven concrete flooring with a polishable concrete overlay. TXP Fast Epoxy Primer, TRU Gray and TRU Self-Leveling Spiked Roller were used on 25,000 sq ft of flooring.
Renovations to CBS Studios required a fast, high-quality underlayment for the finished floor. The area was laser-surveyed in order to meet requirements that the final surface be extremely flat. TRU Self-Leveling and TXP Fast Epoxy Primer were used on 2,000 square feet of floor space.
The expansion and renovation work included replacing the tile flooring in parts of the church with a polishable concrete overlay for a high-sheen, salt-and-pepper finish. TXP Fast was applied first. Then TRU Self-Leveling Natural and TRU Self-Leveling Gray were blended together and mixed with fine aggregate. The TRU was polished to a 1,500-grit finish.
An integral colored, polishable concrete topping was installed in the restrooms of the Cincinnati Music Hall. TXP Fast Epoxy Primer was used followed by TRU Self-Leveling Natural with integral color. The crew diamond-polished the floor to a 400-grit finish.
TRU Self-Leveling was applied at about 3,000 square feet per hour, with two crews working back-to-back 12-hour shifts. Prior to TRU, TXP Fast Epoxy Primer was applied at 24 mils on the profiled substrate.
The flooring of the newly purchased space needed to be rehabbed to match both the higher elevation and the polished finish of the restaurant’s existing concrete floor. Concrete Mix, Concrete Leveler and TRU Self-Leveling were used. By using Rapid Set products, polished concrete flooring was able to be installed in less than a week’s time.
The project owner wanted the building’s walls and floors to look like exposed concrete. Skim Coat was used as the underlayment to level and smooth the concrete substrate. 40,000 square feet of polished concrete overlay in the entrance and lobby were installed with TRU Self-Leveling. Gray pigment was added to match the flooring to the walls.
The floor of a lobby that has a high volume of traffic was first leveled from 1/4 inch to two inches then polished and stained. Products used were Acrylic Primer, LevelFlor, TXP Fast Epoxy Primer, and TRU Self-Leveling.