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Posted by on in Polished Concrete Flooring

Concrete Polishing : Best way to treat concrete surfaces.

'Polished concrete eliminates the need for continually replacing your flooring, making it a value for money proposition' says Parmeet Bhalla  Director, BGSB Concrete Solutions Pvt Ltd

Concrete polishing is steadily becoming the preferred choice of those looking for the ultimate no-wax/ epoxy flooring material. Thanks to recent advances in polishing equipment and techniques, concrete floors, both old and new, are attaining high-gloss finish that never needs waxes or coatings. The superior durability and performance of concrete mean that it is not surprising that an increasing number of retail, warehouse, and office facilities are opting for polished concrete flooring.

Almost any concrete slab can be polished, regardless of its age. Moreover, no special acid agents are required in order to prepare the surface. The initial preparation consists of 5 or more steps of surface grinding. This is done in order to achieve a dense surface. Polishing with resin diamond grids subsequently follows this procedure. Additionally, based on specific requirements, lithium based floor hardeners and penetrating surface densifiers are also used for arriving at the right sheen.

Choosing an Applicator

Polishing concrete is a specialized job and therefore, is best done by an experienced applicator. They will ensure that the slurry is kept off your property, ensuring a tidy and clean work area. It is therefore important that you choose an experienced concrete flooring contractor if you are planning a new concrete pour for your factory, warehouse or office facility. One good way to select an experienced applicator/contractor would be to go through referrals. They are one of the honest sources of information that can help you zero in on an experienced applicator/contractor.

Value for Money

Polishing concrete and using lithium based densifiers will actually harden the surface of your concrete floor and not slippery, which makes them the preferred choice for factories, warehouses, offices and residential units globally. Polished concrete eliminates the need for continually replacing your flooring, making it a value for money proposition. There are certain specific steps that are taken in order to ensure that areas such as bath and showers, where high moisture is an issue, the floor is made more slip proof, than any other flooring material. This is done using an impregnated sealer, which through its penetrative action permeates into concrete pours. This in turn results in a scour finish that acts as an anti-slip surface, without compromising on the aesthetics.

Earlier single sealers were being used in the process of polishing concrete. Since the slab tends to hold the cold within, the use of single sealer was often inadequate to address issues related to thermal efficiency of concrete. Today, a combination of three sealers, known as 'sandwich' is used in the process of polished concrete flooring. A penetrating sealer first of all penetrates and seals all the pours. This reduces the phenomenon of temperature rising to the surface. The application of an additional shield coat protects against mechanical damage. The final coat ensures the durability of the flooring, for years to come without removing any of the sealers, while also preserving the sheen of the floor.

About the Author:

Parmeet Bhalla is the Director of BGSB Concrete solutions Pvt Ltd, a leading concrete polishing and toppings service provider in the country. BGSB' office is based in New Delhi and leads BGSB's vision of re-facing floors all over the country. BGSB'S services range from Super flat Flooring, Polished Concrete, stamped concrete, Acid Staining & self level floorings. The company has over the years served hundreds of national and international clients, who without hesitation will endorse the brand, serve qualities at BGSB. The company specializes in all areas of concrete re-surfacing from: restoring, decorating old or new concrete inside and out. Whatever the task may be one can be assured that BGSB will provide the highest service in accordance.

For more on BGSB and its services their senior project manager can be reached at +91 99112-33099 or mail at: This email address is being protected from spambots. You need JavaScript enabled to view it.

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Posted by on in Polished Concrete Flooring

Concrete Curing Options:

1. Water Cure

  • Flooded
  • Ponded
  • Mist Sprayed

Water curing is the most effective method for curing concrete. Not the best option for Decorative Concrete work as thismethod is prone to efflorescence causing discoloration. Works well for standard gray concrete, or concrete that will be usedfor polished surfaces.

2. Water Retention Methods

  • Sand
  • Canvas
  • Burlap
  • Straw

Keeping the above stated options continuously wet or damp during the curing period will allow concrete to fully hydrate. Not the best option for Decorative Concrete work as this method is prone toefflorescence causing discoloration. Works well for standard grayconcrete, or concrete that will be used for polished surfaces.

3. Waterproof Plastic Film

Heavy mill plastic Applied as soon as the concrete is hard enough to resist surface damage. Plastic film may cause discoloration of the concrete-do not apply to concrete where appearance is important.

Exception - Plastic over imprinted concrete with Release Powder.

4. Cure / Cure and Seal

Stryenated Acrylic Products (both WB and SB)

The chemical application should be made as soon as the concrete is finished or the day after the concrete is poured and Powder Release is removed.

Cures should meet ASTM standard 1315.

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Posted by on in Polished Concrete Flooring

Concrete Joint types

  • Freshly placed concrete is always prone to cracking off inside corners.
  • Spacing Recommendations no more that 2-3 times the size in inches
  • 4 inch thick slab need joints that are 8-12 feet on center
  • 2” slab = 4 to 6 foot joints
  • 5 cm slab = 2 meter squared joints
  • 4” slab = 8 to 12 foot joints
  • 10 cm, slab = 3.5 meter squared joints
  • 6” slab = 12 to 18 foot joints
  • 15 cm slab = 5 meters squared joints

What is the difference between a construction joint, isolation joint and control joints?

CONSTRUCTION JOINT

Joints in concrete pavement are created by forms to end one concrete pour and start another. If a pour is too large to cast at one time, workers set forms to complete the pour and then remove them to join the next placement to the old one. The cleanest way I have ever seen a construction joint placed is by using a small edger (the smallest you can find) on the first pour. This edger will be used to create a slightly rounded edge on the exterior formwork of the slab. From there your next pour will be finished to the existing height of the first pour and not edged. The next morning come back and use a framing chalk line to mark a straight line on the construction joint and saw cut the joint open. This will look like the two slabs were poured at the same time and saw cut later.

ISOLATION JOINT

"Isolation joint" is now the preferred term instead of "expansion joint, "even though you order "expansion joint" at supply houses. The function of these joints is to isolate your work from structures, other pavements, and objects considered to be non-movable. An old concrete guy once told me concrete is not going to get any bigger than at the time of placement, so expansion material is not needed in the body of a placement and is unsightly. Isolation joints provide space for slab movement around perimeters. The joint material should be resistant to deterioration, should be wide enough to extend to the full depth of the placement, and it should be 1/4 inch to 1 inch in thickness.

CONTROL JOINTS

Control joints allow for movement and proper cracking. Temperature change and poor sub base preparation contribute to slab movement. When the concrete cracks,we want to have an active role in deciding where it will crack and that it will crack in a straight line instead of randomly. Control joints can be cut at the time of placement or the next day with a diamond saw blade.

Cut joints deep enough. Cut joints 25% of the depth of the slab. A 4" thick slab should have joints 1" deep if cut the same day. Control joints are cut a minimum of .33 times the concrete thickness if cut the next day.


How to cut joints- Saw cut joints using a diamond blade and high rpm diamond saw. When Saw cutting joints, the concrete should be cured enough as to not ravel or destroy the edges of the saw cut. Hand jointers can be used to tool joints into fresh concrete, but this is not as architecturally pleasing for Decorative Concrete.

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Posted by on in Polished Concrete Flooring

Preventing Concrete Cracks
“WHY CONCRETE CRACK”

Poorly compacted or prepared sub-grade:

Excavations beneath the slabthat are not to be filled with concrete (usually plumbing or other mechanical trenches) should be brought back to grade in compacted lifts. This means a 24" (60 cm) trench would be back filled 6" (15 cm) at a time, each "lift" being mechanically vibrated so it is left compact. If these excavations are not compacted when backfilled, this loose soil will settle over time leaving the concrete over that area with no earth under it. This becomes a prime place for concrete to settle and crack.

Excess water in the mix:

Concrete requires very little water to hydrate properly.Typically concrete flat work is poured with toomuch water. For every pound (or kilogram or any unit of weight of cement, about 0.25 pounds (or 0.25 kg or corresponding unit) of water is needed to fully complete the hydration reactions. This requires a water-cement ratio of 1:4often given as a proportion: 0.25. However, a mix with a w/cratio of 0.25 may not mix thoroughly, and may not flow wellenough to be placed, so more water is used than is technically necessary to react with the cement. More typical water-cement ratios of 0.4 to 0.6 are used.

Rapid Drying of the concrete:

Water that is not consumed by the hydration reaction may leave the concrete as it hardens, resulting in microscopicpores that will reduce the final strength of the concrete.Concrete slabs can shrink as much as 1/2 inch per 100 feet (1.5cm per 30 meters). This shrinkage causes forces in the concrete which literally pull the slab apart. Cracks are the end result of these forces. Rapid drying of the slab significantly increases the possibility of cracking.The chemical reaction, which causesconcrete to go from the liquid or plastic state to a solid state, requires water. This chemical reaction, or hydration, continues to occur for days and weeks after the concrete ispoured.

Improper strength concrete poured on the job:

Concrete is available in many different strengths. Verify what strength the concrete you are pouring should be poured at.

(Example)

4000 psi concrete with air - Cold weather mix
3000 psi concrete no air - warm weather mix

Lack of control joints:

Control joints are planned cracks – Control joints allow for movement and proper cracking. Temperature change and poor sub base preparation contribute to slab movement. When the concrete cracks, we want to have an active role in deciding where it will crack and that it will crack in a straight line instead of randomly. Control joints can be cut at the time of placement or the next day with a diamond saw blade. (When installing decorative concrete work saw cuts are preferred over hand tooled joints).

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Posted by on in Polished Concrete Flooring

Now Introducing superflat Concrete floors in India which will facilitate smooth and quick VNA (very narrow isle) movement within your warehouses and factories.