Ironing of concrete and concrete surfaces: when it is necessary to do this, types and technology

Because of its strength and adaptability, concrete is one of the most often used building materials. But getting the best results out of concrete surfaces frequently calls for particular treatments, like ironing. This procedure improves the concrete’s durability and appearance by refining the surface finish. Although it’s not always required, ironing can have a big impact in some circumstances.

Concrete must be ironed in order to achieve a hard, smooth surface. This is especially crucial in places like driveways, sidewalks, and industrial floors where the concrete will be subjected to environmental factors and traffic. By sealing the surface, the procedure lessens the chance of dusting, cracking, and other types of damage over time. A well-ironed surface is also a great option for both indoor and outdoor applications because it can be easier to clean and more stain resistant.

Concrete can be ironed using a variety of techniques, each appropriate for a particular set of circumstances and curing stage. For instance, troweling is a frequently employed technique soon after the concrete is poured. It entails smoothing and compacting the surface with a trowel, either by hand or with a power trowel. Using a float is an additional technique that can help to further smooth the surface by elevating finer particles to the top. Sometimes extra procedures like sealing or polishing are needed to get the right degree of durability and smoothness.

Getting the best results from ironing concrete requires knowing when and how to do it. A properly polished concrete surface can greatly increase the material’s lifespan and lower maintenance costs. It’s not just about appearances either. The quality and longevity of your concrete surfaces can be greatly improved by using the proper ironing techniques and timing, regardless of the size of your project—commercial or residential.

The essence of the procedure

The tiny pores that form when screed is poured are sealed during the ironing process. You can obtain a long-lasting coating by using specific compounds that, after being applied to the surface, react with the top layer.

The following are used for floors made of concrete:

  • compositions based on high-grade cement;
  • colloidal solutions with liquid glass;
  • polymer-based products.

The technology shouldn’t be abused when processing concrete surfaces. It is essential to abide by the processing guidelines and the manufacturer’s recommendations if you want your floor to be long-lasting and extremely durable.

  • increased water resistance;
  • increased strength;
  • surface leveling;
  • prevention of cracks;
  • reduced risk of delamination and fragility of concrete;
  • ready-to-use coating.

To improve the longevity and aesthetics of concrete structures, ironing concrete and its surfaces is a crucial procedure. It entails compacting and smoothing the surface to get rid of flaws, boost wear resistance, and produce a consistent finish. When a smooth, polished appearance is desired, this technique is especially important for floors, driveways, and other exposed concrete areas. There are several ways to iron concrete, including troweling and using power tools; each is appropriate for a different concrete work stage and type. Concrete surfaces can be made to last much longer and look better by knowing when and how to apply these techniques.

The following surfaces can be treated with this procedure:

  • concrete screed in parking lots;
  • floors in premises (garage, warehouse or production);
  • areas near entrances on the street;
  • concrete paths;
  • blind areas;
  • new or old cement coatings.

Ironing methods

Several processing techniques exist:

  • dry;
  • wet;
  • colloid with penetration into the structure of the base.

The dry option is thought to be easier, but it needs cement, which is the primary ingredient in the mixture. This method’s low cost is one of its advantages.

Liquid compositions containing cement, polymer compositions, and colloidal mass are used in the wet method. The manufacturer’s instructions specify the technology used to prepare the solution. Even though the wet method and colloid application are more involved, they can be done at home.

Ironing concrete with your own hands

Select a mixture that will strengthen the surface. It is advised to use: at home

  • cement grades M400 and higher;
  • cement-sand mortar (in a ratio of 1:1), for greater effect, add lime (1/10 part);
  • special ready-made solutions intended for the wet method;
  • dry polymer mixtures.

Use the following to raise the compositions’ caliber:

  • basalt;
  • sodium aluminate;
  • quartz;
  • corundum;
  • stainless steel.

Additives should not make up more than 1% of the mass of dry matter. Pigment is occasionally added to the coating to give it a lovely appearance.

Dry ironing

Cement is used in its production, along with specific fillers. Before the concrete has had time to set, this technique is frequently applied to horizontal surfaces in freshly laid concrete.

  • sifted dry cement (sometimes dry sand is added in a 1:1 ratio) is applied to a wet concrete screed;
  • the thickness of the cement layer should not be more than 3 mm;
  • wait until the water remaining in the screed soaks the applied mixture;
  • treat the surface (until its color becomes dark gray) using a trowel, steel trowel, spatula, shovel (special grinding machines when ironing a large area).

The hardening process requires one week or so. The method’s drawback is that it cannot be used on vertical surfaces because the dry components will fall off of them.

Wet ironing

The following order is followed when using the ironing technology:

  1. Prepare the solution: mix sand with cement (in a 1:1 ratio) and water. Bring it to a consistency resembling thick sour cream.
  2. To improve plasticity, it is allowed to add lime milk (in a 1:10 ratio to the amount of cement). Adding liquid glass increases moisture resistance indicators, gives additional smoothness to the cement coating.
  3. Apply a liquid mixture in a layer of about 5 mm.
  4. Level the layer with a trowel or spatula.
  5. After hardening, polish with a grinding machine.

Although the wet method requires more work, it can be applied to both vertical and horizontal surfaces.

Dry and wet polymers

A more costly but practical approach that makes use of powdered polymer mixtures. One notable distinction between polymer compositions and sand-cement mixtures is their ability to be used in air temperatures as low as -25°C.

Polyurethane-based compositions are the most popular. Moreover, liquid compositions (sealers) are used for coating if a high surface strength is needed.

These kinds of compositions have the following benefits:

  • high adhesion to compositions made on the basis of concrete;
  • good penetrating qualities;
  • increase wear resistance, strength, waterproofing of the concrete base.

They can be utilized in public spaces, both residential and commercial. Dry mixes are less expensive than pre-made solutions. It uses the same technology as dry ironing. A requirement is that they can only be used after pouring freshly mixed concrete that hasn’t had time to dry.

First, the powder is sifted, then applied in a thin layer to the surface of the concrete, and rubbed in. One drawback to this processing method is that excessive humidity in the concrete screed can cause an uneven layer to form, which can complicate final grinding.

The type of filler must be considered when selecting a composition. The strength is adversely affected by the composition’s predominance of small particles. The mixture loses its plasticity and absorbs moisture unevenly if large particles are predominant.

When Ironing is Necessary Types and Technology
Ironing is needed when a smooth, durable surface is desired, especially for floors or pavements. Types include dry, wet, and mechanical ironing. Technology involves using trowels or special machines to press and smooth the surface.
It helps in reducing dust and improving wear resistance. Wet ironing uses water to create a slurry for better smoothness, while dry ironing involves pressing dry materials.

In order to guarantee the longevity and aesthetic appeal of concrete surfaces, ironing is an essential step. This must be done in order to shield the concrete from deterioration, moisture, and other environmental elements. Ironing prolongs the life of concrete by generating a dense, smooth surface that resists water penetration, surface dusting, and cracking. In high-traffic areas, where the concrete is exposed to frequent use and possible damage, this process is especially crucial.

There are several ways to iron concrete, and each works best in a particular circumstance. In order to achieve a hard, smooth finish, dry ironing entails applying a dry cement mix to the surface and then mechanically troweling it. A cement and water slurry is applied and worked into the surface during the wet ironing process. Both methods seek to create a barrier against the outside world by sealing any pores and thickening the outer layer.

The type of concrete, the desired finish, and the particulars of the project site all influence the method choice. Using the appropriate technique is crucial if you want the best outcomes. Concrete that has been properly ironed improves the material’s longevity and performance in addition to its aesthetic appeal. Through comprehension and application of suitable ironing methods, we can guarantee that concrete surfaces maintain their strength, durability, and aesthetic appeal for an extended period.

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Dmitry Sokolov

Chief engineer in a large construction company. I have extensive experience in managing construction projects and implementing modern technologies.

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