How to cover (treat) a concrete floor so that it does not dust

Although concrete floors are strong and adaptable, dust issues can occasionally arise. In addition to being an annoyance, this dust may be damaging to your possessions and hazardous to your health. Fortunately, there are a number of efficient ways to treat concrete floors to stop dust from rising.

The most widely used remedy is the use of concrete sealers. There are several varieties of sealers, including polyurethane, acrylic, and epoxy, and each has special advantages. These sealants create a barrier that shields the surface from dust accumulation and facilitates easy cleaning of the floor.

Using a concrete densifier is an additional efficient technique. By penetrating the concrete, densifiers initiate a chemical reaction that fortifies the surface and minimizes dust. When extreme durability is needed, this treatment is frequently applied in commercial and industrial settings.

Consider painting or staining the concrete if you’re looking for a more aesthetically pleasing option. These treatments give you the ability to alter the floor’s appearance in addition to sealing the surface. They give your place a polished, dust-free appearance while also adding aesthetic appeal and functionality.

A dust-free concrete floor doesn’t require difficult upkeep. You can benefit from a cleaner, safer, and more appealing floor for many years to come by selecting the appropriate treatment.

What causes dust formation

The first thing to do when considering how to treat a concrete floor to prevent dusting is to research the process of dust formation and assess the quality of the screed. Large amounts of dust frequently appear for other reasons besides the natural processes taking place in concrete. The top layer, which is constantly dusty and is sensitive to loads, mechanical effects, and chemical reactions, progressively deteriorates as tiny particles are released.

It is important to remember that over time, dusting can occur even with a concrete solution that has been properly mixed, poured, dried using technology, and exhibiting excellent qualities. Even though the amount of dust produced may be less than with a low-quality screed, it is still an issue that cannot be solved, particularly in situations where there are high loads, active operation, or exposure to abrasive materials on the layer.

Erosion of the top concrete layer causes dust to appear. Because the components of the hardened solution differ, the porous structure of the hardened monolith collapses when even small loads are applied.

If the erosion process is not halted in a timely manner, it will eventually affect the deep layers of concrete as well as the surface, causing the floor screed to partially and eventually completely collapse. The concrete screed’s service life is drastically shortened.

The appearance of dust on an untreated concrete floor during operation is detrimental to both human health and equipment performance. Tiny cement and chemical particles irritate the skin and eyes, settle in the lungs, and can trigger allergic reactions.

Regarding the mechanisms, a concrete floor that isn’t regularly dusted can quickly wear out the units and tools, leading to failure. Like fine sand, dust collects in cracks and on parts, and it frequently leads to improper equipment operation. It’s also crucial to remember that a dusty floor needs frequent cleaning, which takes time, effort, and effort.

Strengthening primers and impregnations

Primers are typically used to get ready for painting or applying a finishing compound to a concrete surface. Three crucial tasks are carried out by deep penetration primer at once: priming, impregnating, and dust removal. Concrete can be shielded from salt and water-based solutions, mineral and inorganic oils, fuel, and detergents by the primer layer. Usually, the composition is applied in one or two layers using a roller or brush (use a spray gun for larger areas).

The mixture binds the particles of concrete, strengthens and resists wear, deters water, and strengthens resistance to the spread of cracks.

The simplest method of cleaning concrete of dust is to treat it with a liquid primer that penetrates deeply, either by impregnation or primer coating. Uzin PE 425 primer, Protexil strengthening impregnation, and Plitonit strengthening concentrate are a few examples of such materials. Although the compositions can greatly reduce the issue of dust, they cannot entirely eradicate it (though this is still adequate for residential spaces to be finished).

The concrete’s tiny pores are sealed when the impregnation is applied to a clean base. Apply one layer at a time, let it dry, then do it again. Concrete is protected from heavy loads by acrylic impregnations, and its strength is further increased by polyurethane primers (although the latter have a strong odor). Although epoxy compounds are costly, they are very durable.

Concrete screeds can be impregnated with polyurethane either alone or in conjunction with paint application. The primer penetrates deeply into the pores of the concrete monolith and sticks to it well. Applying enamel made of the same material and covering the floor with polyurethane impregnation is the best course of action.

Additionally, epoxy primer and epoxy paint can be used separately or in combination. produces a very sturdy and well-dusted layer.

Dry composition topping

Is a dry mixture that is used to dedust and strengthen freshly poured screed. The ingredients used to make toppings are cement, plasticizers, and fixatives. Metal particles can be added to the composition to increase the strength. The topping works on a straightforward principle: using a special grinding machine, a portion of the powder is poured onto a damp surface and rubbed into the thickness of the monolith. Two to three passes are usually made.

The topping makes the floor wear-resistant and ready for use without the need for a finishing coat. It also completely removes dust and triples the strength of the concrete screed. Such compositions have a number of drawbacks, including the expensive nature of the topping itself and the requirement for concrete grinding and polishing equipment.

This technique is most frequently applied to floors in commercial and industrial settings where, because decorative finishing is not present, the concrete surface needs to be given optimal performance characteristics and made aesthetically pleasing. Following treatment, the concrete is durable, comfortable, flawlessly even, and free of all dust.

Sikafloor 2 SynTop (Russia), Neodur HE2 (Germany), and Weber.floor HB plus/Cerinol HB Korund Plus (Germany) are a few topping examples.

Technology of applying topping

Study the grouting guidelines and the directions on the material’s packaging before creating a topping-coated floor. The number of passes is determined by the requirements and floor condition, and the mixture consumption may vary depending on the manufacturer and compositional ingredients. The work involves the use of specialized grinding equipment and concrete grinding machines, sometimes known as "helicopters."

• After pouring the screed, wait 3-4 hours – the readiness of the concrete for work is checked by the footprint on the thickness (if the screed is not pressed through much, you can start).
• The topping is poured into a special cart, evenly scattered over the floor area.
• The powder absorbs cement milk and excess moisture from the concrete.
• Next, the topping is rubbed into the base using a trowel so that not a trace of dry powder remains on the floor surface.
• The procedure is repeated several times, each time the surface is carefully rubbed and sanded.
• After the screed has hardened, it is rubbed and treated with liquid impregnation.

By doing this, you can create the longest-lasting, dust-free coating possible with excellent technical qualities and a lengthy service life.

A concrete floor must have the surface properly sealed or treated to prevent dusting. Dusting can be successfully avoided by sealing the concrete with an appropriate concrete sealer, using a concrete densifier, or applying a particular concrete coating. By decreasing the porosity of the concrete and preventing the fine particles from breaking away, these treatments produce a protective layer. By doing this, you prolong the floor’s life and improve its appearance of cleanliness and polish. For many years to come, a dust-free concrete floor can be guaranteed with proper upkeep and recurring sealant applications.

Paint application

Concrete floors can also be painted, but paint should only be applied after one or two coats of primer or impregnation have fully dried. In order to ensure compatibility and the best outcome, primer and paint are typically chosen based on the same substance.

Enamel group

Modern compounds that have been modified or regular colored enamels can be used to coat concrete floors. In the work, a roller or brush is used; a spray gun is used less frequently (when processing large areas). In this manner, a smooth, glossy finish that is resistant to acidic and alkaline solutions, water exposure, medium-level loads, and chemicals is achieved.

The coating will wear off quickly when applied to a garage or industrial building’s floor. Furthermore, the protective layer is thin and has a low ability to withstand shock loads. These paints’ principal benefits are their ease of application and comparatively low cost.

Acrylic enamels are the most cost-effective and long-lasting in this class; they produce a protective waterproof film on the surface, are odorless, toxin-free, and have a fairly high level of abrasion resistance.

Heavy-duty garages and rooms are painted with modified dyes. These are made using polymer resins, specifically acrylic, urethane-alkyd, acrylate, and epoxy. Examples are epoxy paint VEPOX, Polyflex, and wear-resistant protective and decorative enamel Texipol.

Although polyurethane compositions offer a small covering layer that needs to be renewed every three to seven years, they are implied to have a high level of resistance to loads. The service life is significantly impacted by use intensity. The compounds come at a high cost. For instance, Duepol, a two-component paint.

Two-component epoxy resin-based paint is the least expensive and most easily applied paint. It provides great strength whether applied to dry or wet concrete. Alkyd-urethane paints are glossy and resistant to wear, but they shouldn’t be used in situations with extremely high loads.

Polymer compositions

The most common application for polymer compositions is the pouring of thin-layer self-leveling flooring. They are suitable for both outdoor and indoor use. Apply a uniform, flawlessly smooth coating in any color. Usually just a thin layer, the screed should already be flawless and smooth if it is being used to remove dust. All that the polymer layer does is fix things.

The seamless coating can be used in temperatures ranging from -35 to +60 degrees Celsius and is extremely hard and wear-resistant. Alkalis, acids, automotive chemicals, solvents, fuels, and lubricants are all effectively resisted by it. A decorative effect can be obtained with the introduction of different fillers (granite chips, quartz sand).

There are two kinds of compositions available on the market: professional universal compositions (fit for use in industrial premises) and compositions for household use (rooms with moderate loads and wear).

Examples of professional compositions are PolimerStone (Russia), ESP 1615, and Teknofloor 2K (Finland); examples of conventional compositions are Ucrete DP and PG-100 (Germany).

Recipe for home craftsmen

You can make a product with your hands to treat concrete floors for dust removal. Although the qualities of floors covered in these materials are frequently not very high, in some circumstances and in rooms with light traffic, this option might be appropriate.

• PVA glue (it is better to take PVA-m or PVA-k) with water in a ratio of 1:8 – mix until a homogeneous solution is obtained, apply to concrete.
• Dilute latex with water (the proportion is selected in accordance with the type of substance).
• Dissolve pieces of foam in acetone or gasoline, add a little xylene. Apply the mixture to concrete – within a few hours the gasoline will evaporate and the polymer will protect the floor from water.

Method	Description
Sealing	Apply a concrete sealer to create a protective layer that prevents dust from forming.
Painting	Use concrete paint to coat the surface, which also helps to reduce dust.
Epoxy Coating	Apply an epoxy coating for a durable, dust-free finish that also enhances the floor"s appearance.
Polishing	Polish the concrete to a smooth, hard surface that is less likely to produce dust.
Concrete Densifier	Use a densifier to harden the concrete, which reduces dust by filling in pores and making the surface more solid.

Keeping a dust-free and hygienic atmosphere requires keeping a concrete floor free of dust. You can prolong the life of the floor and drastically cut down on the amount of dust produced by properly treating the surface.

Using a concrete sealer is one of the easiest and most efficient ways. Sealers create a barrier that shields the surface from dust accumulation. Sealers come in a variety of forms, such as acrylic, epoxy, and polyurethane. Every variety offers advantages, so it’s critical to select the one that best suits your requirements.

A concrete densifier can be used as an alternate strategy. In order to create a harder surface, densifiers pierce the concrete and react with the free lime. This improves the longevity of the floor and lessens dusting. Densifiers are a durable and simple-to-use method of controlling dust.

Frequent upkeep is also very important. Regularly mopping and sweeping the floor aids in the removal of any dust that may accumulate. Another way to lessen the quantity of dirt and dust brought into the space is by using mats at the entrances.

You can guarantee a dust-free, clean atmosphere by selecting the appropriate treatment and taking good care of your floor. Maintaining your concrete floor will be made easier by following these steps, regardless of whether you choose to use a densifier, sealer, or a combination of the two.

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