Concrete Polishing and Grinding User Guide

by | Apr 8, 2019 | Blogs, FAQ

Complete Polishing Package

Equipment
  • 1x FTR Grinder / Polisher, 110v, inc drive disc and dust skirt
  • 1x TV120 Industrial Vacuum, 110v, inc 7m of hose
  • Stages 1 & 2 Diamond Grinding Segments
  • Stage 1 to 5 Polymer Polishing Buttons
  • Spektrin Lithium Plus Floor Sealer / Hardener
Optional Equipment
  • 1x 5 Kva 110v Transformer for the FTR Grinder
  • 1x 5 Kva 110v Trans former for the TV120 Industrial Vacuum and Hand Grinders
  • 120 Grit Metal Bonded Segments
  • 3000 Grit Polishing Pads
  •  5” Hitachi Grinder / Edger 110v
  • 5” Diamond Disc 110v
  • EPO Hand Held Diamond Polisher
  • Stages 1-7 EPO Polishing Pads

FTR Grinder / polisher, this 110v machine comes complete with a drive disc and a dust skirt. It requires a 5kva, 32A  transformer, extension lead must be 32A and maximum 15M long.

For dust free operation use a TV120 110v industrial vacuum connected  to  the FTR Grinder. The TV120 will require a 5kva transformer.

The following notes describe the typical processes carried out to achieve a high gloss finish on a suitable surface. Every concrete floor is different and the process may have to be varied depending on site conditions. When changing from the metal bond diamonds to the resin hybrid based diamonds it can be advantageous to include an additional stage of the resin hybrid at 100 grit.

Fault detection of the surface:

1.With a floor cleaning machine and vacuum remove all dust and dirt.

2.Identify all defects (holes, chips, cracks) on the clean, dry surface.

The polishing process:

All Edging, edge polishing must be done at the same time as the polishing process.

3. Perform the initial stage 1 grind using metal bond diamond tools, 30/40 grit. This will expose the surface aggregate. If the surface layer is extra thick then it is recommended to use 16/25 grit tools before the 30/40 grit diamonds. 

  • Use grinding/polishing machines at an average speed and making 3-4 passes over the area depending on the surface condition. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding

4. Repair any defects (holes, chips, cracks) with a suitable filler (B&Q supply a concrete repair filler, U.Can High Strength Concrete Repair)

  • Application instructions for the filler are indicated in the relevant technical specifications.

5. Continue grinding with stage 2 metal bond diamond tools, 80 grit to remove swirl marks and scratches evident after the initial grinding.

  • Use grinding/polishing machines at a moderate speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding

6. Polishing the surface with polymer bond diamond tools, 50 grit. – Note on large (250m+) jobs you can use the 120 Grit metal grinding segments for a more cost effective process.

  • Use grinding/polishing machines at a moderate speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding.

7. Polishing the surface with polymer bond diamond tools, 100 grit.

  • Use grinding/polishing machines at a moderate speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding.

8.Polishing the surface with polymer bond diamond tools, 200 grit.

  • Use grinding/polishing machines at a moderate speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding.

9. Application of colourant onto the clean and dry surface (if colour is needed).

  • Procedure for applying colours is described in the relevant application instructions.

10. Removal of excess colourant and application of impregnating sealer SPEKTRIN or SPEKTRIN LITHIUM on dried (coloured) surface.

  • Procedures for applying SPEKTRIN or SPEKTRIN LITHIUM are described in the relevant instructions.
  • When completely dry (not earlier than 2 hours for SPEKTRIN LITHIUM, and 12 hours for the SPEKTRIN) it is necessary to again clean the floor with a cleaning machine or industrial vacuum cleaner.

11.Surface processing with polymer bond diamond tools 400 grit.

  • Use grinding/polishing machines at a moderate speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding.

12.Polishing the surface with polymer bond diamond tools 800 grit.

  • Use grinding/polishing machines at a fast speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding.

13.Polishing the surface with polymer bond diamond tools 1500 grit.

  • Use grinding/polishing machines at a fast speed and making 2-3 passes over the area. Each pass to be at 90 deg. to the previous.
  • Then clean the floor with a cleaning machine after wet grinding or with a vacuum cleaner after dry grinding.

14.Application of SPEKTRIN PLUS or SPEKTRIN LITHIUM PLUS with a thin layer onto a dry, clean surface.

  • Procedures for applying SPEKTRIN PLUS or SPEKTRIN LITHIUM PLUS are described in the relevant instructions.

15.Finish polishing / Buffing of the surface.

  • Polishing is performed not earlier than 12 hours after application of the SPEKTRIN PLUS or SPEKTRIN LITHIUM PLUS. Additional weights may have to be added to the handle of the grinding machine to lighten the weight on the grinding head. Use felt or other pads similar to horsehair that are light coloured.
  • The final polish is carried out at maximum speed.

The above is applicable for concrete slabs aged over 28 days.

This document presents updated information, but as we cannot be present and monitor the use of the material and the compliance process, we are not liable for any loss or damage caused by misuse. Prior to commencing we recommend the installation of a test area for the detection of possible nuances and characteristics of a particular floor, as well as to agree the final result with the client.

FTR grinder/ polisher £140 pw*
TV120  industrial vacuum £100 pw*
5Kva transformer £20 pw*
3Kva transformer £15 pw*
125mm Hitachi grinder £14 pw*
EPO Hand Polisher £50 pw*
16A Extension lead £5 pw*
32A Extension lead £7.50 pw*
Metal bond diamond tools 30/40 grit £33 / mm used
Metal bond diamond tools 80 grit £33 / mm used
Metal bonded diamond tools 120 grit £33 / mm used
Hybrid resin polymer polishing tools 50 grit £95.25
Hybrid resin polymer polishing tools 100 grit £95.25
Hybrid resin polymer polishing tools 200 grit £95.25
Hybrid resin polymer polishing tools 400 grit £95.25
Resin polymer polishing tools 800 grit £85.90
Resin polymer polishing tools 1500 grit £85.90
125mm diamond grinding disc, 30/40 grit £48
EPO Hand Polisher pads 50-1500 grit £132
Spektrin Lithium  – 5L Drum
(approx 50-70 M² / 5L drum diluted to 10L of Spektrin)		 £62

pw* Per Week

All prices are plus VAT

Example Costs – 30-50 M² Kitchen polished and edged to 1500 grit, sealed with Spektrin hardener would cost around £1200 +delivery and vat.

Example Costs – 200 M² Office / showroom polished and edged to 1500 grit, sealed with Spektrin hardener would cost around £1700 +delivery and vat.

Example Costs – 450-500 M² Large showroom / office block polished and edged to 1500 grit, sealed with Spektrin hardener would cost around £3600 +delivery and vat. (estimated 2 weeks work.)

The above examples are estimations, the actual cost could be more or less depending on the quality of the concrete. Wear rates and tool life are all determined by the condition of the concrete. The above examples are by no means a guarantee.

The metal bond diamond tools will typically grind around 500 M² depending on the quality of the concrete. For costing purposes you can calculate £33 wear charge for 50 M² in each grit level.

The costing guide includes diamond tools through to 1500 grit. Should you decide to go a stage further to 3000 grit we can deliver these on a next day service. If you decide 400  grit gives the finish required then any unused diamonds returned will be refunded.

The FTR machine can polish to within approximately  25mm of the wall. If you have to polish right up to the wall then you will need the hand grinder and EPO polisher.

Delivery/Collection on the complete package is charged at £80 + VAT

The equipment is shipped in a steel stillage for protection, a refundable deposit of £100 + VAT is payable to ensure safe return.

For more information please contact us on T: 01405 862688 – E: [email protected]