Concrete grinding – processing methods

For concrete surfaces to be smooth and long-lasting, concrete grinding is an essential step. The longevity and appearance of concrete can be greatly improved by using this process, whether it is for floors, countertops, or other concrete structures. Comprehending the diverse techniques of concrete grinding can aid in attaining optimal outcomes for your particular undertaking.

Concrete can be ground using a variety of methods, each with advantages of its own. While some techniques are ideal for larger, more complex tasks, others are better suited for smaller, more focused projects. By investigating these various methods, you can select the one that most closely matches your requirements and yields a superior finish.

Concrete grinding not only enhances appearance but also aids in removing flaws like old coatings, stains, and uneven areas. This improves the surface’s appearance and gets it ready for additional procedures like sealing or polishing. Effective concrete grinding can be done by anyone with the correct equipment and training, making it a necessary ability for both pros and do-it-yourselfers.

Types of concrete grinding

The appearance of a polished concrete surface coated with polyurethane varnish is comparable to that of polished stone and self-leveling flooring. Concrete is also easier to repair and has a higher resistance to damage. The treated surface is not susceptible to dust, moisture, or harsh environments; residential buildings can have these types of floors installed on them.

Concrete can be processed using two different technologies: wet and dry grinding. For the task, the same supplies and equipment are utilized.

Wet grinding

Ideal for granite filler and high-strength concrete. This approach costs more because it uses more consumables. Up to a 5 mm thick layer of upper concrete can be removed by wet grinding.

It is challenging to use a hand tool because a specialized water suction device must be used to remove water from the work surface. The floor being processed is covered in wet dirt; grinding errors become visible only after the dirt has been removed or dried.

Dry grinding

A layer of concrete up to 2 mm thick is removed during the dry processing step. Wearing protective gear for the eyes and respiratory system is necessary because of the amount of dust this produces.

Concrete can be ground dry more quickly and with less effort than it can be ground wet. Dust settles quickly, allowing you to evaluate processing quality and make corrections right away.

Grouting fresh screed

Hard surfaces in open areas and long-lasting, wear-resistant floors in commercial and industrial spaces are made possible by this technology.

A grouting machine with a diesel, gasoline, or electric engine that can be operated manually or autonomously is called a helicopter for grinding concrete. The screed is processed 4–20 hours after laying with its assistance. This makes it possible to compact the top layer, which is then enhanced with toppings made of cement.

Rough grinding is followed by 10–16 hours of finishing. A dust-proofing impregnation is simultaneously rubbed onto the concrete’s surface. Fresh screed processed by helicopter leaves a smooth, fracture-resistant floor surface. The topping contains pigments for aesthetic purposes.

Tools for grinding concrete

Concrete surfaces can be processed using the following methods:

• industrial grinders (convenient for large surface areas);
• household grinders (suitable for use at home);
• angle grinders (a grinder can be used to grind the floor in small rooms and hard-to-reach places).

A grinder is the most readily available for use at home. Working with a tool that has two handles and a substantial weight is most convenient. Select a model with a casing that can be connected to an industrial vacuum cleaner hose for dust-free concrete grinding.

Consumables for angle grinders

For grinding concrete, there are numerous kinds of attachments available:

1. Cups. They are discs with a recessed center. Their purpose depends on the shape of the working surface:

• with square pads – for rough processing with cutting off protruding fragments of concrete;
• with a double segment – for uniform removal of the top layer;
• with boomerang-shaped pads – for final polishing of the surface.

1. Disks (circles). Have a flat surface with an abrasive applied to it:

• with large and medium-sized diamond chips – for rough grinding;
• with small chips and a cellular structure (turtles) – for polishing.

1. Frankfurts. Special trapezoidal attachments. Depending on the type and characteristics of the working surface are used for grinding or polishing concrete floors.

A crucial step in improving the durability and appearance of concrete surfaces is concrete grinding. It entails smoothing and leveling the surface while eliminating flaws and outdated coatings using specialist equipment and methods. This enhances the concrete’s visual appeal and gets it ready for further treatments like sealing or polishing. Gaining knowledge of the various concrete grinding techniques, such as wet and dry grinding, as well as the necessary equipment can help get the best results for a range of applications, from industrial to residential floors.

Stages of work

Regardless of the grinding technology selected, the surface must first be prepared. To carry out this:

• remove the old coating (if any);
• remove protruding reinforcement;
• drill holes if they are provided for by the project (drilling after grinding will spoil the appearance of the finished floor);
• fill up potholes and cut off the bumps revealed when checking the evenness of the surface using a 3D ruler;
• check the rigidity of the fresh screed – grinding work can be carried out only after gaining strength, otherwise the attachment to the grinder will tear out pieces of concrete, clinging to the filler.

Removing defects

Concrete cracks are widened, dust-free, and primer-treated. then smoothed with a rule after being filled with a cement-based repair mortar. Utilizing the same idea, eliminate cavities and depressions. A diamond disk is used to cut irregularities larger than 5 mm and remove dust.

Grinding process

Concrete is diamond-ground using abrasive wheels with varying fractions of cats: 25–30 units are used for preliminary grinding, and 40 units are used for finishing grinding. Polishing discs with abrasive crumbs of 1500–3000 units are used to give the surface a gloss.

1. The prepared surface is impregnated with a special strengthening solution.
2. The floor is ground in several stages with a decrease in the size of abrasive particles until smooth using a dry or wet method. In the second case, it is generously watered before processing.

Read the instructions carefully before using a household or industrial grinder (you can rent one). An angle grinder is used to process the floor in difficult-to-reach areas.

If you use a grinder to grind the entire surface, you must stop every ten to fifteen minutes to prevent the tool from breaking from overheating.

The polished floor is finally dried and free of pollutants. After that, it is painted or varnished with polyurethane or concrete paint in two to three layers, drying in between.

Conclusion

With concrete grinding, you can produce a premium coating that can withstand heavy loads and operate for decades. You can use common household tools to complete the task yourself at home. It is crucial to select the appropriate attachments while keeping in mind the concrete’s strength properties and filler percentage.

Concrete grinding is a useful and adaptable technique that improves the look and performance of concrete surfaces. This method can turn dull, rough concrete into a smooth, beautiful, and long-lasting finish for residential, commercial, or industrial uses. It’s a necessary step in the creation of polished concrete floors, which are well-liked for their high durability, low maintenance, and visual appeal.

There are various techniques for grinding concrete, and each is appropriate for a particular set of circumstances. Wet grinding is recommended for indoor projects where dust control is essential, while dry grinding is best for large, open areas and requires less cleanup. Furthermore, handheld grinders make it possible to work precisely around intricate edges or in confined spaces. The specific project requirements and the state of the concrete surface will determine which approach is best.

Concrete grinding can enhance surfaces’ longevity and safety in addition to their aesthetics. It gets rid of surface flaws like pits and bumps, which can cause trips. Smoothing the surface also improves the resilience and lifespan of the concrete by preparing it for further treatments like staining or sealing.

In the end, concrete grinding is a workable way to enhance concrete surfaces in a variety of situations. You can obtain a high-quality finish that satisfies both your functional and aesthetic requirements by being aware of the various techniques and how they are applied. Concrete grinding offers a dependable way to improve and preserve your surfaces, whether you’re upgrading a home floor, a commercial space, or an industrial area.

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