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Concrete surface profiling is a critical step in ensuring the longevity and performance of coatings, overlays, and other flooring systems. The right equipment and techniques can make a significant difference in the quality of the final result.
Profiling though can mean dealing with a variety of quite different issues, Unfortunately, in surface preparation, there is no one machine that's appropriate for all projects, some machines work well on some concrete surface issue and not on other issues. In this blog, we will explore the appropriate equipment for various profiling tasks, including…
- removing ledges and high spots.
- Repairing spalled concrete surfaces.
- Repairing spalled edges.
- Profiling for coatings.
- Achieving the most monolithic results.
- Polished concrete.
- Achieving surface flatness.
- Selecting the fastest methods.
Lets get started...
- Removing Ledges…
Ledges in concrete surfaces can be dangerous, a tripping hazard and unsightly and will definitely “Telegraph” through any material installed over them. Ledging also creates challenging if not insurmountable conditions for tile setters. So, what equipment is best for removing these irregularities?
Recommended type of Equipment…
Concrete Shavers… Shavers use a drum of multiple blades that “Shave” the concrete to the desired depth, this method is Ideal for removing high spots and ledges with precision. They can shave down concrete to a consistent level, ensuring a ledge free finish.
Scarifiers… These machines use rotating cutting wheels to “Slap” or “Flail” the surface removing concrete to varying depths. They are excellent for more aggressive removal of thicker ledges but do leave a verry rough Concrete Surface Profile, or (CSP).
What equipment would NOT be a good choice...
- Shot Blasters
Recommended Equipment for removing ledges…
Bartell Global’s…
- CT320 shaver/scarifier
- CT250 shaver/scarifier
- BEF200N Scarifier
CLICK HERE FOR MORE INFORMATION ON SCARIFIERS AND SHAVERS
- Repairing Spalled concrete surfaces…
Spalled surfaces occur when the surface of the concrete breaks away, flakes, or chips away from the surface often due to freeze-thaw cycles pore concrete mix or heavy impact. Repairing these surfaces requires equipment that can effectively remove the top damaged layer of material and prepare the surface for new overlay.
Recommended type of Equipment…
Concrete Grinders... Equipped with diamond grinding tooling segments, these machines can smooth out spalled areas and create a uniform surface as long as the damage is not too severe.
Concrete Shavers… For deeper spalling, shavers can be used to remove more substantial amounts of material compared to grinders before applying an overlayment.
What equipment would NOT be a good choice...
- Shot Blasters
- Scarifiers
Recommended Equipment for spalled concrete surfaces…
Bartell Globals…
- Predator P800PRO or the P650PRO planetary grinder with a set of aggressive diamond segments, 16 – 25 grit.
- CT320 Shaver
- CT250 for smaller areas
- Repairing Spalled joints…
Spalled concrete joints are areas where the surface edge of the concrete has flaked, cracked, or broken away, typically at the edges of control and start-stop joints. This damage often occurs due to various factors such as freeze-thaw cycles, heavy traffic, excessive joint movement, or poor initial concrete installation. These influences can cause the surface to spall or break off. Spalled joints not only compromise the structural integrity and aesthetic appeal of the concrete surface but also pose safety hazards. Timely repair and maintenance are essential to prevent further deterioration and ensure the longevity of the concrete slab.
Recommended type of Equipment to repair spalled concrete edges…
Concrete shaver… one with the ability to adjust down the width of the cutter drum.
What equipment would NOT be a good choice for repairing spalled concrete edges...
- Shot Blasters
- Scarifiers
- Diamond grinders
Recommended Equipment to repair spalled concrete joints…
- CT320 Shaver
- CT250 Shaver for smaller areas.
The drum in these machine are fully customizable, most of this type of repair calls for just a 4” wide cut and this is easily done with both the CT320 & CT250.
SOME EXAMPLES OF A FULLY CUSTOMISABLE CT320 DRUM
- Profiling for Coatings…
Proper profiling is essential for coatings to adhere correctly. The surface must be roughened to the appropriate degree (Concrete Surface Profile or CSP) without causing excessive damage to the surface or too high of a CSP rating.
Recommended type of Equipment…
Shot Blasters… These machines propel steel shot at the concrete surface, breaking the surface away to create a rough profile, ideal for coatings. They are efficient and provide consistent results with a high production rate.
Concrete Diamond Grinders… For a less aggressive profile, diamond grinders can create a smoother surface while still ensuring adequate adhesion for coatings. Planetary diamond grinders are a great choice for low build epoxies because they do not leave "Corn Rows" that could "Telegraph" through a this mill surface and be astatically unacceptable.
What equipment would NOT be a good choice...
- Scarifiers
- Shavers
these types of equipment, in most projects, leaves too aggressive of a CSP for most epoxy coatings that are low build to even most high build materials.
Recommended Equipment...
Bartell Global’s,
Predator serries of Diamond Grinders… P650 & P800 Planetary grinders, both available in Propane or electric versions. Planetary grinders and the Alpha & DFG280 single head grinders for smaller projects.
CLICK HERE FOR MORE INFORMATION ON PLANETARY DIAMOND GRINDERS
Shot Blasters… SPE12ES and Modul 300 for bigger jobs and the Elephant and the SPE9ES for smaller projects.
CLICK HERE FOR MORE INFORMATION ON SHOT BLASTERS
- Achieving the Most Monolithic Results…
For applications where a seamless, monolithic appearance is crucial, the right equipment will make all the difference.
Recommended Equipment...
- Planetary Diamond Grinders… When equipped with fine-grit diamonds, these grinders can produce a smooth, monolithic finish.
What equipment would NOT be a good choice...
- Scarifiers
- Shavers
- Shot Blasters
these machines leave perceivable "Corn Roes" in the surface of the concrete that then must then be removed with a Planetary Diamond Grinder.
Recommended Equipment…
Bartell Global’s,
Predator series of planetary grinders, P650 & P800 in both Propane and electric as well as the P550, P650, and the P750 “Y” Series electric Planetary Grinders.
- Polishing concrete…
Polishing the concrete surface has grown incredibly in the last 10-15 years and shows no signs of slowing down. The reason is that it makes for a beautiful, long-lasting, low-maintenance, eco-friendly, and cost-effective concrete floor option.
Recommended Type of Equipment…
Planetary Grinders…
What equipment would NOT be a good choice...
- Scarifiers
- Shavers
- Shot Blasters
NOTE... some highly trained contractors will use Shot Blasters & Shavers as a first pass on verry hard concrete surfaces to open the surface for the polishing process but this method can easily damage the surface of concrete making it hard to impossible to polish afterwards. so the use of these machines are left to the highly trained, experienced professionals only.
Recommended Equipment to Polish Concrete…
Bartell Global’s,
Predator series of planetary grinders, P650 & P800 in both Propane and electric as well as the P550,650, and 750 “Y” Series electric machines.
- Achieving Concrete Surface Flatness…
Flatness, the removal of high spots or Suttle undulations in concrete often referred to as "Bird Baths" is essential for many flooring applications, including those requiring high-performance flooring systems, floating floors, and large profile tiles.
Recommended type of Equipment…
- Concrete Shavers /Planers
- Planetary Diamond Grinders
What equipment would NOT be a good choice...
- Shot Blasters
- Scarifiers
Recommended Equipment…
Bartell Global’s,
Predator series of planetary grinders, P650 & P800 in both Propane and electric as well as the P550,650, and 750 “Y” Series electric machines.
Concrete Shavers, CT250 & the CT320 concrete shavers.
- Fastest Profiling Methods…
Time is often a critical factor in concrete surface preparation. The fastest methods combine efficiency with effectiveness.
Recommended type of Equipment…
Shot Blasters… By far the best option, Shot Blasters are known for their speed and ability to cover large areas quickly while still providing excellent surface profiles.
Big Planetary Diamond Grinders… While not what I would consider "Rapid" These grinders can remove material and create a suitable profile in a relatively short amount of time. generally speaking, the bigger the machine is, the faster it will profile the concrete. selecting the correct diamond segments play a critical roll in production rates.
What equipment would NOT be a good choice...
- Smaller equipment, single head grinders and small Shot Blasters
Recommended Equipment for fastest profiling concrete…
Bartell Global's
- Predator series of planetary grinders, P650 & P800 in both Propane and electric as well as the P550,650, and 750 “Y” Series electric machines.
- Shot Blasters… SPE12ES and Modul 300 for bigger jobs and the Elephant and the SPE9ES for smaller projects.
Conclusion…
Choosing the right equipment for concrete surface profiling depends on the specific task at hand. Whether you need to remove ledges, repair spalled edges or surfaces, prepare for coatings, achieve a monolithic finish, ensure flatness, or complete the job quickly, there's a machine designed for the job. Investing in the appropriate equipment not only enhances the quality of your work but also improves efficiency, ensuring successful project outcomes every time.
For more tips and insights on concrete surface preparation and related subjects, be sure to follow our blogs at Bartellglobal.com and stay tuned for our next post on advanced concrete profiling techniques.
CLICK HERE FOR A DEEPER DIVE INTO SURFACE PREPERATION EQUIPMENT