Using a concrete grinder is something that I always wanted to do when I started working at Bartell Global. A friend of mine needed a hand removing some glue off of a floor and I thought, hey this cant be so hard, lets give it a go! I knew the theory of concrete grinding pretty well, so I thought I was pretty prepared after talking to some of our grinding experts. The short version of this story is that I actually was pretty prepared.
Concrete grinding is actually a lot easier than I thought it was going to be. Obviously, this depends so much on what you are trying to do and the circumstances, but the basic operation of the machines was easier than expected. I definitely had some issues that if avoided, would have help the job go faster and the results would have been better. In this blog, I am going to share a few of the things I learned during this process to help you avoid some of the mistakes that I made.
I have a pretty good understanding about diamond bonds and grits, but have never had to put that knowledge to the test. I had to experiment with a few different types before I found one that worked well and achieved the result I wanted. If I would have used the wrong diamonds, I can only image the mess I would have made.
My recommendation when starting your first few grinding jobs is to take diamond selection very seriously. This means properly understanding bonds and segment styles, as well as testing the concrete hardness if you have the ability to. Also take into account if you are removing something on top of the concrete and what you plan to do with it after. If you are going to be polishing the floor after you remove glue for example, you have to make sure you use diamonds that dont scratch the floor beyond repair.
By nature, I can be a bit impatient. This is not a helpful trait to have when grinding concrete, especially when you are removing glue that is tough to get off the floor. At the beginning of the job, I was taking my time and getting all the glue off in one pass. As the night went on, I wanted to finish up and began to go a bit faster than I probably should have. This resulted in having to go back over some areas multiple times to get the glue off fully.
Because pretty much all these larger grinders need more than household power. Depending on where you are in the world, the power needed will change. You will either need a proper generator or an electrician to come and pull the right power.
This is not a last-minute thing to take care of. I found out 2 days before the job started that I would be grinding and that was cutting it close. Communicate with the supplier on what the electrical requirements are if you dont know and also make sure that you know which type of plug is on the grinder. Someone could come and hook the power up properly, but if they dont put the right plug on, you will be in the same situation.
Before you start grinding make sure that you think about the pattern you are going to do and how the vacuum hoses and power cords will affect your path. I didnt really think too much about where I had the vac in the room until later on and it wastes a bunch of time having to stop grinding and move the vacuum back and forth. The Ermator vacuum I was using was able to be pulled by the hose from a distance, but will all the cords on the ground, I would easily get tangled and have to go do it manually.
The area that you should have your vacuum and cords will differ depending on the size and shape of the room that you are grinding. Make sure you take some time to think about how the pattern you will be grinding in will be affected by the cords and vacuum.
Plain and simple. Grinding right up the wall or posts is probably the worst part about the grinding process in my opinion. You basically have 2 options. You can use a hand grinder and be on your hands and knees for hours or use a smaller walk behind grinder that has edging capabilities. We were using the DFG 280 to edge which worked pretty well, but it is tedious work.
Because you are using a smaller grinder that doesnt have as much weight on the diamonds, it took us longer to remove the glue from this area. You also have to be careful about how you blend to the two grinding paths together so that you avoid a different look when applying a finish.
All in all, grinding that floor gave me a new perspective on what a lot of you go through every day and I have a lot more respect for all you concrete grinders out there. If youre a pro, I am sure you learned these lessons just as I did, but if you're just getting into the game, hopefully thinking about these things before you start will help to avoid some wasted time and money on your first few jobs.
Industrial sampling campaigns were arranged for different grinding chemicals.Performances of each chemical were evaluated.The influences on milling and classification units were discussed.Economic evaluations were performed.A methodology on selecting the most feasible chemical was developed.
Within the study, the results of the test works performed around a cement grinding circuit in order to select the most appropriate option are presented. In this context, sampling campaigns were arranged with different grinding aids and mixed products then the influences were discussed by considering the changes in production rate, equipment performance, energy consumption, cement quality and clinker saving parameters. The results implied that the production rate of the circuit and the 28-day strength of the cement could be increased by 24% and 3.5% respectively with the selection of an appropriate chemical. In addition, the use of chemicals may reduce the clinker consumption by 5% that is important regarding to CO2 emissions. The studies concluded that triethanolamine based chemical had better performance parameters than the other types.
Regular readers will know that, at the very least, youve got to be looking to remove the top layer of laitance and surface contamination - but, whats the best way of doing that and how do you know youre doing it well?
Ill start of by saying that while there are other effective means of preparation, the average epoxy contractor in the residential, retail and commercial fields should be able to tackle most jobs with only a diamond grinder at their disposal. While this may sound like good news in a way, just putting any old grinder with any old discs onto concrete unfortunately does not guarantee a successful outcome. The performance of your grinder and the quality of your surface preparation is largely controlled by two concepts you need to develop a basic understanding of: hard and soft concrete.
To explain these terms and the impact they have, Ill cite some material published by Floorex - a specialist surface preparation company Ive had a bit do with over the years and always respected for the educational approach they bring to their field. They describe hard concrete as follows -
When we talk about hardness (to grind) it really is all about the kind of dust that is produced during the process. Hard concrete tends to produce ultra fine, talcum powder fine dust. This dust is very un-abrasive; it does not wear the matrix of the diamond segment sufficiently. The result is that the diamond grit soon becomes hardly exposed so it grinds even finer, powdery dust; the segment ceases to grind, and the segments may even get hot and glaze over. They go on to list some handy rules of thumb you should keep in mind when dealing with this type of concrete -
Grinding soft concrete requires hard bond discs that resist the metal matrix being eroded away. The sandy, gritty, abrasive dust will erode many discs abnormally fast, so be certain that you are using the right disc. More than any other time, grinding soft concrete is when contractors fail be aware of the signs of rapid grinding and fast wear to stop work and rectify the problem.
Perhaps the biggest message they try to get across is that every slab is different and you cant fall into the trap of thinking that one disc will be good enough for every job you do. Even the best or biggest machine wont get satisfactory results if incorrect discs are used and youll benefit greatly if youre willing to go through a little trial and error at the start of a project.
The other point they make is a personal favourite of mine because I see big similarities with the use of cheap resins. In this case, contractors tempted by the lower price of budget discs will have to put up with discs that work over a relatively narrow band of hardness and have less concentration of diamond grit in them.
In Grinding, selecting (calculate)the correct or optimum ball sizethat allows for the best and optimum/ideal or target grind size to be achieved by your ball mill is an important thing for a Mineral Processing Engineer AKA Metallurgist to do. Often, the ball used in ball mills is oversize just in case. Well, this safety factor can cost you much in recovery and/or mill liner wear and tear.
Powerful, vigorous, and reliable, Xtreme Polishing Systems' extensive selection of surface preparation equipment was specifically designed for any project size, whether it be residential, commercial, or industrial settings. Concrete has been a key player in most structural engineering and construction industries, and over recent years concrete has been exceeding popularity in flooring. Polished concrete systems and decorative concrete flooring have truly evolved with innovative developments in concrete surface prep equipment and machinery. Xtreme Polishing Systems concrete equipment is built to last and was specifically designed to grind, polish, level, smooth, clean, and repair concrete surfaces. We offer a versatile selection of concrete floor grinding machines, polishing machines, edging machines, floor scrubbers, floor burnishers, floor scrapers, industrial vacuums, and equipment package deals.
If you want your floors to last longer and shining brighter then you should consider a decorative epoxy coating for your surfaces. Our epoxy is a resinous, self-leveling material applied on concrete surfaces to yield beautiful decorative finishes for residential and commercial settings. Epoxy coatings offer a reliable, aesthetic, and high-performance surface guaranteed to capture the attention of clients, guests, and more. Over the years an industrial-grade epoxy resin has been developed to bond to surfaces like concrete to protect them from damage and corrosion while obtaining beautiful color variations to completely revolutionize your surfaces. Xtreme Polishing Systems offer epoxy coatings, polyaspartic/ urethane topcoats, garage floor coatings, metallic epoxy, powder epoxy, and industrial glitter applications.
Polished concreteandepoxy flooringare becoming increasingly popular as more people ditch normal concrete floors for decorative ones. This trend is expected to continue as decorative concrete floors come with many benefits. For one, they are very durable. These floors are also aesthetically appealing and are a welcome break from the traditional plain concrete floors. It also helps that epoxy and polished concrete floors are among the cheapest flooring services available for both commercial and residential properties.
While these two flooring options are great, the installation has to be done right for the users to enjoy the full benefits. That is where we come in. We provide both epoxy floor and polished floor training. We are keen to equip all our students with the skills that will turn them into experts in this field. The best way to excel in any industry is to learn by doing. Our certified trainers are available to provide insight every step of the way with one on one training in an air-conditioned warehouse space. We extend our support to guide you through the most efficient ways to operate the requiredmachinery,equipment, andtoolsfor a successful job.
By guaranteeing a floor for life, Xtreme Polishing Systems specializes in turn-key, one-stop-shop products including floor grinding machines, floor polishing machines, diamond polishing pads, concrete densifiers, concrete sealers, epoxy resin coatings and protective urethane topcoats, concrete dyes, stains, and much more to assist you in completing a concrete floor from start to finish. We provide a full product line of do-it-yourself supplies, equipment and building materials for projects big and small. XPS is committed to 100% customer satisfaction throughout the ordering and shipping process. We offer price matching on products, secure checkout and most supplies ship out same day.
The construction industry generates a huge demand for cement. The selection of cement is mainly dependent on efficiency and low cost. Cement grinding aids are used to improve the efficiency of cement production and reduce energy consumption. Cement grinding aids have been used for improving cement clinker grinding efficiency, power flowability, and strength development of binders. Moreover, cement grinding aids have positive effects on the mechanical properties of cement, such as setting time, compressive strength, surface area, and mortar workability. Cement grinding aids are classified into three key types based on the feedstock, such as amine-based, alcohol-based and ether-based grinding aids.
The prime factor behind the usage of cement grinding aids is the elimination of the coating effect of clinker on grinding mill walls and to increase the production rate of cement keeping the surface area constant. Also, cement grinding aids are utilized to allow transportation in delivery trucks and storage in silos without lump formation.
Increasing urbanization and population are expected to drive the growth of the construction market. Strong desire to develop more reliable constructions like malls, buildings, organizations, industries, laboratories, etc. can be considered as a major driving factor for the global cement grinding aids market in recent years. Strong support of the government in numerous activities like construction of bridges, roads, dams, etc. results in high demand for efficient cement to increase the durability of these constructions. This factor is ultimately fueling the demand for cement grinding aids throughout the forecast period. Cement grinding aids avoid lump formulation of in silos. Storage in silos is a vital need for the transportation of cement.
The relatively high-product cost and the presence of alternatives to cement grinding aids act as a restraining factor for global cement grinding aids. However, key manufactures of cement grinding aids are focusing on strategic developments such as collaborations, expansion, product developments, acquisitions, etc. to gain high traction in the global market. For example, in Nov17, GCP Applied Technologies Inc. (manufacture of cement grinding aids) introduced its innovative product, a grinding aid (TAVERO- brand name) which eliminates the water injection requirement and pre-hydration of cement.
Geographically, the global cement grinding aids market can be segmented into seven key regions such as Latin America, Europe, Middle East & Africa, South East Asia Pacific, Japan, China, and North America. The Middle East and South East Asia Pacific regions are anticipated to remain key regions in the cement grinding aids market throughout the forecast period. The emerging economies like India and China are achieving new highlights in the global cement grinding aids market.
The global cement grinding aids market is expected to be fragmented due to the medium to high presence of international and local market players. Some of the cement grinding aids market participants identified across the value chain of global cement grinding aids market which is as-
The global cement grinding aids market research report presents a comprehensive assessment of the market and contains thoughtful insights, facts, historical data, and statistically supported and industry-validated market data. It also contains projections using a suitable set of assumptions and methodologies. The global cement grinding aids market research report provides analysis and information according to market segments such as geographies, application, and industry.
Persistence Market Research (PMR), as a 3rd-party research organization, does operate through an exclusive amalgamation of market research and data analytics for helping businesses ride high, irrespective of the turbulence faced on the account of financial/natural crunches.
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You could replace your uneven concrete pavement with a new slab or level it using a leveling compound. But a more straightforward solution is grinding concrete floor. Youll end up with a pavement that lasts longer and looks like new.
Theroots of treesplanted too close to a driveway can buckle the concrete. Concrete pathways can also become stained over time from moss, fallen leaves, and colored garden mulch. If a property has inadequate drainage, rainfall can turn a sidewalk into a waterfallover time, this causes wear on the concrete.
Everything from shoes and bicycles to cars and trucks will wear down a concrete driveway or pathway over time. And, of course, theres always the possibility that the service professional who installed the original sidewalk just didnt do a good job.
First, the grinding surface should be cleaned of all moss, dirt, and other debris. If the concrete is moldy or stained with car grease, its worth giving it a once-over witha degreaseror concrete cleaner.
Grinders are high-speed machines. Theyre loud, and they have the potential to kick up rubble and dust from the concrete. Even though youre working outside, dont forget to prepare somesafety essentials.
If youre refinishing a large area, such as a concrete patio or driveway, youll save time using a more robust tool. There are two main options when it comes tofloor grindersfor substantial outdoor stretches: single and dual disc grinders and planetary grinders.
Dual disc grinders feature two separately spinning discs. Since theyre larger than a single-disc concrete grinder, the operator can work over a wide area quickly. Consider a dual-disc option if youre dealing with an outdoor space larger than 1,500 feet.
When it comes to more minor spots, such as a cracked walkway in the front yard, choose a single-disc concrete grinder. These lightweight 15 amp machines can be plugged into a residential outlettheres no need for propane or gas power like a dual-disc grinder.
Each discon this industrial-sized grinder spins separately around a central point. Though they can be used for large outdoor areas, they are typically best when you need to polish a floor. If you need to refine the surface of an outdoor sidewalk, work your way through the grit levels of your discs: from 18 grit right up to 120 grit.
Since concrete is a natural, porous material, its vulnerable to wear and tear over time. When youre planning to grind a concrete sidewalk, the first step is to make sure the customer knows this fact. They need to know that concreteneeds resurfacingoftenanywhere between eight to fifteen years in a typical environment.
Slightly slope the concrete back from the lip or edge of the crack to create a smooth surface. Finish off to a smooth surface using a dry hand grinder. Again, you can attach a vacuum to collect theharmful silica dustif you want, though this isnt always necessary when youre working outside.
Once youve finished grinding the concrete pathway down to the necessary level, the concrete in the worked area will appear lighter in color and have more aggregate showing through than the older concrete surrounding it.
One of the grinding techniques used by experienced concrete professionals is to square off the area. So long as the un-ground concrete nearby is left untouched, this will create anaesthetically pleasing finish.
Grinding a sidewalk is the fastest and cheapest way to repair an unsafe outdoor trip hazard. By using the right machinery and tools for grinding concrete floor, youll end up with a sidewalk thats durable and has a smooth, non-slip surface, not to mention a happy client that will keep coming back to you again and again.
No matter how new OR clean the concrete is, it will need a rough textured surface in order to achieve maximum epoxy adhesion. The rougher the better. There are many ways to etch (or roughen) the surface of the concrete: Acid Etching (using muriatic acid or our etch n' clean solution), Grinding the surface with a Floor Grinder/Scarifier, or Shot Blasting. Though Acid Etching is the easiest, it can sometimes take multiple applications to sufficiently etch the concrete then you have to allow it to dry. More and More flooring contractors use a Floor Grinder with diamond plates to roughen up the concrete because it doesn't take as long as the acid prep. You can roughen the floor, sweep the debris away, and apply your epoxy in one day and it roughens the concrete much more effectively. Also, if your coating concrete that has been sealed with a sealer, it is necessary to use a floor grinder to prepare the concrete. Using the grinder will open up the pores of the concrete to allow the epoxy to sink in, therefore achieving maximum adhesion.
No matter how new OR clean the concrete is, it will need a rough textured surface in order to achieve maximum epoxy adhesion. The rougher the better. There are many ways to etch (or roughen) the surface of the concrete: Acid Etching (using muriatic acid or our etch n' clean solution), Grinding the surface with a Floor Grinder/Scarifier, or Shot Blasting.
Though Acid Etching is the easiest, it can sometimes take multiple applications to sufficiently etch the concrete then you have to allow it to dry. More and More flooring contractors use a Floor Grinder with diamond plates to roughen up the concrete because it doesn't take as long as the acid prep. You can roughen the floor, sweep the debris away, and apply your epoxy in one day and it roughens the concrete much more effectively.
Also, if your coating concrete that has been sealed with a sealer, it is necessary to use a floor grinder to prepare the concrete. Using the grinder will open up the pores of the concrete to allow the epoxy to sink in, therefore achieving maximum adhesion.
Grinding machines are indispensable equipment in cement plants. In the process of cement production, the cement plant needs to complete the grinding of pulverized coal, raw meal powder, and cement products. The purpose of grinding is to increase the specific surface area of the material and reduce the particle size of the powder, so as to achieve the activity required by the next process.
Tube mill has been used as the main grinding equipment in the cement industry for a long time, and it is still widely used because of its simple structure, easy operation, and low price. However, the energy utilization rate of tube mills is only 2% ~ 20%, which is very low. With the continuous development of grinding technology, there are two kinds of cement grinding equipment with lower energy consumption, one is vertical roller mill, and the other is roller press.
Both the vertical roller mill and roller press apply the working principle of material bed milling. During the grinding process, only a small part of material particles directly contact with the grinding parts of the mill; but under the action of grinding parts, material particles form a material bed, and through the stress transmission and interaction between the particles, they are cracked, broken, and crushed.
For vertical roller mill, the grinding parts are rollers and grinding disc. The pressure required for grinding mainly comes from the rollers. At present, the loading force is mainly formed by hydraulic pressure. The material is fed into the grinding disc from the center or side of the upper housing, and the material layer is formed in the process of moving on the grinding disc. When the material passes between the roller and the grinding disc, the grinding is completed under the extrusion and shear force between them.
For roller press, the grinding parts are two rollers of the same size. The materials fall vertically from the top to the two rollers to form the material bed. Under the extrusion force of the two rollers, materials are ground to fine particles. There are two transmission modes of roller press, namely double drive, and single drive. The double drive roller press is the more popular type. The transmission device of a single drive roller press has only one set to drive one roller, and the other roller is driven by connecting with the former one with a gear train.
In a vertical roller mill, the material on the grinding disc is restricted by the air duct ring, but the side of the material between roller and disc is not restricted. In roller press, in addition to the restriction between the two rollers, side baffles will also be set on the sides of both ends of the roller, which will limit the side of the material bed of the roller press.
Because the grinding area of the roller press is restricted from all sides, the increase of applied energy will also increase the fine powder and specific surface area of material. But for vertical roller mills, the growth rate of that of material will gradually decrease. From this point of view, roller press is superior to vertical mill.
In a vertical mill, there generally are two or more grinding rollers. The contact area between the grinding roller and the grinding disc is large, and the energy utilization rate is higher than that of the roller press. Moreover, the materials are generally milled on the grinding disc by several grinding rolls repeatedly. From this point of view, the vertical mill is better than the roller press.
When grinding cement products, a grinding system composed of a roller press or an external circulation vertical mill + a powder concentrator + a tube mill is generally selected. Taking grinding P o42.5 cement as an example, the pre grinding closed-loop system composed of roller press or external circulation vertical mill and powder concentrator has a circulation load rate of 200% 300%, and the specific surface area of the selected materials is 180-280m2 / kg. The following table lists the main machine preparation and the product particle size of several cement grinding systems.
The particle shape of the materials from the roller press and the vertical roller mill is also different. The vertical mill grinds the material by two forces, the extrusion force and the shearing force between the roller and the grinding disc; the roller press grinds the material by only one force, the force between the two grinding rollers. When the material is ground to a certain fineness, most of the fine powders from the vertical mill are irregular and prismatic, and the fine powders from the roller press are mainly irregular flake and strip particles. From the particle shape, the fine powder from vertical mill is closer to that from tube mill, and the fine powder from vertical mill is more suitable for making cement products than that from roller press.Get in Touch with Mechanic