1. Coarse grind the concrete with either 20 or 30 grit diamonds to expose the aggregate (a full set of diamonds should be used to obtain a flat floor). The appropriate metal bond selection is critical to assure economic diamond tooling costs and labor productivity. Wet grinding may also be appropriate.
2. Remove first-step scratches with 60 grit diamonds (again a full set should be used). If the concrete seems to have significantly more holes than usual you can grout at this stage with 60 grit diamonds, (the grouting process is explained in step 3) and this will ensure that all holes will be filled once you have completed step 3 with the 120 grit diamond segments.
3. Remove second-step scratches with a half set of 120 grit diamond segments and combine the grinding process with Effidense filling compound as follows:
l. Wet the concrete to remove the ’suction’/absorption from the concrete floor.
al. Apply Effidense to the floor using a broom. Approximate usage should be 5 litres per 25 m2 (1500 sq/ft per 5 gallon). Begin with 5-10 lineal metres (16-32 ft) only in front of the grinder to prevent the Effidense from drying out.
bl. While still wet, run the floor grinder machine with 120 grit diamonds through the wet Effidense. When using the floor grinder, set the speed 600RPM. The Effidense will combine with the dust created by the 120 grit metal bond diamond segments and it will be forced into holes created by air-bubbles and extracted aggregate.
lV. Grind at operator speed to remove all the remaining Effidense filling compound residue. The floor should appear slightly ’blue’ after completing an area. When using Effidense filling compound, work in areas of 5-10 m2 (50-100 sq/ft) until a feel for the process has been established, then allow to dry before continuing with step 4.
4. Apply Effihard liberally with a very soft broom or sprayer. If spraying, make sure to follow with a broom to work the product into the pores of the concrete. Apply Effihard liberally so that the concrete is saturated but without forming puddles. Approximate usage should be 5 litres per 25 m2 (1500 sq/ft per 5 gallon).
- Once the Effihard has dried, a second coat may be required if the concrete is very soft and still absorbent. Again, spread out any puddling with a soft broom.When applying one coat to hard concrete or two coats to porous concrete, the floor should always appear damp/wet for 15-20 minutes after the application of Effihard. If this is not the case, another coat is required.
- Allow Effihard to dry completely before moving on to the next step. A period of 6 – 12 hours is recommended as a minimum to ensure a maximum cure of the Effihard product. The curing time will vary significantly with extreme temperatures – in cold environments it will take longer and in warmer environments it will be shorter.
Note: We recommend the application of Effihard after the final metal bond step as the concrete is most porous after the metal bond diamonds. Effihard will penetrate into the concrete best following the metal bond step. This will ensure the hardest possible surface is achieved.
Note: We do not recommend removal of wet excess hardener with a squeegee or scrubber once it begins to gel off. For maximum saturation and hardening of the concrete surface, it is recommended that the hardener be left in contact with the concrete until completely dry.
5. Remove excess cured/dry Effihard using 50 grit NHD new hybrid bond diamond polishing pads.
- Apply a thin layer of Effihard with a microfibre applicator about 2-5 metres (5-20 ft) in front of the machine, ensuring that the dried EffiHard has turned to a gel-like state. This will not only make the 50 grit NHD new hybrid bond diamond polishing pads more aggressive, but by reactivating any of the excess Effihard it will minimize the possibility of cured Effihard covering over the 120 grit metal bond scratches that are to be removed. To enhance the final gloss level, the same process can also be done before the NHD new hybrid bond diamond polishing pad in step 4.
- If this thin layer is too wet when grinding, there may be excessive wear of the NHD new hybrid bond diamond polishing pads.
Ensure that any excess Effihard is removed completely. In its unreacted state, dry excess Effihard can cause the following problems if left on the floor:
- It will create brown/dark and unsightly patches in the floor when polished using dry resin polishing pads.
- If it comes into contact with water it will reactivate and become very slippery.
- It will cause dull patches or ’clouds’ in the finished product as Effihard will not polish up to the same degree as the harder concrete.
If the use of the 50 grit NHD new hybrid bond diamond polishing pads is unsuccessful at removing excess Effihard (this would be the case if puddling Effihard was left to dry/cure on the surface), use 100 grit NHD new hybrid bond diamond polishing pads in a semi-wet grinding fashion with water. Then move on to step 6 with 100 grit NHD new hybrid bond diamond polishing pads.
Note: When polishing concrete, we do not recommend grinding higher than 120 grit metal bond tools.
- The crossover from metal bond to NHD new hybrid bond diamond polishing pads is the most important stage of the polishing process as far as scratch removal is concerned. The longer the metal bond diamonds are used, the more chance scratches will be made in the floor by the metal bond step (as opposed to the diamond abrasive in the metal bond step).
- Resin bond diamond pads (generally) have significantly higher production rates than metal bond tools. The sooner you begin with resin bond diamonds, the more efficient the production rate.
Note: We do not recommend the use of metal bond diamond tools once the Effihard has been applied:
- Use of metal bond tools can remove too much of the densified surface, leaving an inconsistent end- result.
- Metal bond tools are more aggressive than resin bond tools and can create new holes/pits in the surface.
If the floor does not appear consistent in gloss/shade after step 5 is completed, a thin or ’enhance’ layer of Effihard can be applied to the floor using a microfiber applicator. This layer should be just enough to wet the surface evenly without puddling. Allow the enhance layer to dry before continuing.
6. Continue the polishing process with 100 grit NHD new hybrid bond diamond polishing pads.
- A thin enhance coat of Effihard with a microfibre applicator about 2-5 metres (5-20 ft) in front of the machine can be applied to boost the final gloss levels.
7. Continue the polishing process with 200 grit NHD new hybrid bond diamond polishing pads.
- There is no significant profit to be gained from applying an enhance coat of Effihard after this step.
8. Continue the polishing process with 400 grit NHD new hybrid bond diamond polishing pads.
- You should notice a sharp refection developing at this stage
9. Continue the polishing process with 800 grit NHD new hybrid bond diamond polishing pads.
10. Continue the polishing process with 1500 grit NHD new hybrid bond diamond polishing pads.
11. Continue the polishing process with 3000 grit NHD new hybrid bond diamond polishing pads.
Note: We do not recommend the use of 3000 grit NHD new hybrid bond diamond polishing pads in high traffic areas or near doorways that connect to an outdoor area. When the floor is wet or dirty these areas can become slippery. Use of the 3000 grit NHD new hybrid bond diamond polishing pads would be for a showroom floor finish only.
12. Apply 2 – 3 coats of Effiguard Premium Enhance penetrating sealer using a microfibre floor sweeper, allowing time to dry between coats. The floor should be fully saturated without any excess to ensure all pores are filled. The use of Effiguard is highly recommended to prevent contaminants from staining the floor. However, in some circumstances, and more so with the repair of previously highly contaminated surfaces, Effiguard will show up previous staining beneath the surface as the concrete pores already having a contaminant in them.
13. Leave to cure fully for at least one hour or until touch dry and then buff off residual Effiguard sealer with nylon buffing pads.
Note: The surface can be ground and polished to tailor to different levels of exposed aggregates and non exposed aggregates and to high or low gloss levels by adding or omitting steps.