Polished Concrete Loading Docks

The loading docks of this logistics facility were in rough shape when we arrived. The cementitious part of the concrete floor had been eaten away so that the aggregate was fully exposed. This is a red flag that this floor may be beyond repair. If heavily soiled and contaminated concrete floors are left unmaintained they can become carbonized and irreparably damaged.

If you are reading this and you have a concrete floor where the aggregate (stone) is starting to show, you should get the problem addressed ASAP. If caught in time, the floor can be fully restored which will provide substantially better durability and life.

We used the Rossi Abrasives 7 grind concrete polishing process on the floor with special attention paid to the first grind. The first grind is the most important step in the process; if the floor is not restored to good condition after this step the process will not have a good result.

The first grind was time consuming but we successfully removed the contaminated surface concrete along with 98% of the gouges and damage caused by pallets and other equipment.

The remaining steps in the grinding process went smoothly and the concrete floor polished well. We used more densifier than normal during the densification process which is normal when a floor is in poor condition.

Approximately 50% of the concrete showed signs of permanent damage. The cementitious part of the floor was below the aggregate which means the grinding came too late. While the floor will still be durable, it will accumulate dirt in the low areas between the aggregate and have reduce life. This could have been avoided by doing the maintenance sooner.

Cleaning is important for all polished concrete floors but it’s even more critical when the concrete has been damaged. The right concrete cleaning product will help extend the life of the polished concrete by emulsifying the dirt so it can be pulled from the floor. It also helps protect and strengthen the cementitious part of the concrete. Cleaning polished concrete with water only will result in a build-up of dirt which will damage the floor.

Call us for more information on polished concrete flooring and maintenance, (647) 544-4143.

Worst Case Scenario Warehouse Floor

This warehouse floor is a good example of a worst case scenario concrete floor. This facility handles vegetable oils and has substantial oil saturation in the concrete. It also had two failing overlays which were hiding about 100 steel studs that had to be cut down. The overlays were likely used to level the floor which was very wavy due to poor concrete installation.

When we began our work, I would have rated this floor a 2 out of 10 with 10 being the best floor. We used a Rossi Abrasives surface preparation system beginning with GS2 dual PCD scrapers to remove the overlays followed by 35SS grinding tools.  A lot of extra time was spent taking down high areas to minimize the waviness of the concrete floor.

The concrete floor looked great once the surface preparation was completed. A substantial amount of patching and repairs were required before the coatings could be applied.

The next stage was the coating application; this was a two coat system with an epoxy base coat and polyaspartic top coat. We applied an oil tolerant epoxy primer as the base coat but unfortunately it failed and had to be ground off. It’s quite rare for this to happen but it does happen and needs to be fully removed.

Starting again we applied a different oil tolerant epoxy base coat which cured without issue. We sanded the base coat and applied a polyaspartic top coat which would provide the durability required for the heavy traffic and oil exposure. This facility handles oil filled totes by forklift so epoxy alone would not stand up well.

The final result was okay but not perfect because of the waviness of the concrete floor. The owner did not feel that pouring a new overlay was a good investment so it was beyond our control.

Overall the new floor was a huge improvement from the starting point, we elevated the floor to a 7/10 which is a reasonable level for a warehouse floor.

There are always valuable lessons learned in tough jobs so it was a good addition to our knowledge base.

Call us for a free quote, (647) 544-4143.