Grinding and polishing methods are used in preparing floor surfaces to achieve a smoother, leveled finish with a glossy sheen. In grinding, coarse abrasives are used to level uneven surfaces, eliminate imperfections, and reveal aggregates. On the contrary, polishing employs progressively finer abrasives to lay a smoother and reflective surface. This involves grinding the top layer, eliminating loose layers, and utilising a liquid densifier to seal pores, preventing rapid absorption.
There are two primary methods of concrete grinding and polishing: “dry” and “wet.” While both share similar principles, they offer distinct benefits, making the choice important for achieving the durable floors.
Dry and Wet grinding and polishing process
Dry grinding and polishing constitute a surface preparation method that uses abrasives without the use of water. The method involves the use of grinding and polishing equipment and specialised tools to grind the concrete surface, incorporating segment type metal bond tools initially and finer resin bond tools for the final shiny finish. One notable characteristic of this method is the generation of dust, necessitating the implementation of effective dust extraction systems.
Dry Grinding and Polishing:
- Metal Bond tools (30, 70, and 120 grit) remove the top layer.
- After 70 grit, liquid densifier is applied and left to cure overnight.
- Post-curing, the 120 grit tool removes excess densifiers.
- Resin bond tools (200, 400, 800, 1500, and 3000 grit) are used progressively.
- 200 & 400 grits enhance floor smoothness, while 800, 1500 & 3000 grits increase gloss.
In contrast, wet grinding and polishing involve the incorporation of water during the grinding and polishing process. This method utilises wet diamond polishing pads or grinding tools, utilising water to cool the abrasives, control dust, and enhance the overall efficiency of the polishing procedure. One distinct feature of wet grinding is its reliance on water for cooling, which reduces heat generation during the process.
Wet Grinding and Polishing:
- Ride-on power trowel used, starting with 50, 100, 200 hybrid tools.
- Liquid densifier applied after 200 grit hybrid, curing overnight.
- Resin bond tools used from 200 to 3000 grit.
- Water used up to 400/800 grit; wet dust extractor
Difference between Dry and Wet concrete grinding and polishing
| Dry Polishing | Wet polishing |
| Deep grinding (aggregate exposure)possible | Deep grinding not possible |
| Gives long lasting gloss | Relatively less life of polish |
| Removes all defects in floors like trowel marks | Multiple passes are required to remove marks |
| Level difference in panels is possible | Not possible to correct level difference |
| Low area coverage per day | Higher area coverage per day |
Note: Gloss can be controlled by stopping the process after 800 or 1500 grit for a matte finish. Similarly, starting with 70 grit tools avoids aggregate exposure.
Different equipment, tools, and accessories are required for dry and wet polishing and grinding. The selection of the right equipment is crucial. Trelawny SPT Ltd. India, based in Pune, Maharashtra, stands out as a leading manufacturer of floor surface preparation equipment and pneumatic tools. Manufactured with superior materials and powered by reliable components, their equipment and tools are designed to meet the most demanding conditions.
Trelawny equipments and tools for dry and wet grinding and polishing
The TCG500- twin head floor grinder
The equipment is designed for medium to large works, including levelling and smoothing concrete, coating removal, and polishing. With dual counter-rotating grinding heads, it ensures balanced operation and flexible tooling for fine adjustment of performance. The grinder comes with dual dust ports for virtually dust-free working and additional weights for increased production. It features Trelawny Vibro-Lo™ vibration reduction for operator comfort and safety, making it a reliable and productive choice for various applications. The equipment comes with consumables and accessories. These include scarifying blocks, diamond grinding blocks, hardwood wedges, additional weights, and power cables of varying lengths. Quick release tooling options, diamond discs, and abrasive blocks cater to different grinding and polishing needs. The grinder is available in electric and petrol options.
The TCG250- heavy-duty single head grinder
The equipment is designed for leveling and preparing small to medium areas. With a flexible grinding head that maximizes diamond contact on rough surfaces, it ensures high productivity. The optimized grinding pressure and speed, along with the angled dust port, contribute to virtually dust-free working. Its heavy-weight construction maintains compactness for excellent performance and manoeuvrability. The grinder, suitable for small and medium jobs, offers fast leveling of high spots, coating and adhesive removal, preparation for new coatings, rain-damaged concrete repair, and polishing various materials. Essential consumables and accessories for the TCG250 grinder include a range of grinding discs with varying grits for diverse applications, diamond tooling for efficient grinding on surfaces like concrete, and dust extraction bags or filters to maintain a clean workspace. Additionally, a spare parts kit containing brushes and belts, quick release tooling (if applicable) for swift tool changes, an optional weight kit for increased aggressiveness, and extra handles for enhanced manoeuvrability are key accessories.
A45- Dust Collector
A powerful vacuum cleaner for dust control in surface preparation applications. With a 60-liter capacity for collecting both dust and liquids, it features three single-phase motors producing a total of 3.5Kw. The A45 is suitable for use with various Trelawny surface preparation equipment, offering fantastic performance and portability. Its detachable bin, optional HEPA filter, and filter cleaning mechanism with a vacuum gauge ensure optimum performance in a compact unit.
Diamond Tools & Accessories
1. Grinding Discs with Different Bond Levels
- 10 Segment Soft Bond Grinding Disc
- 16 Segment Soft Bond Grinding Disc
- 20 Segment Soft Bond Grinding Disc
- Medium Bond and Hard Bond options available
2. PCD Removal Diamonds
3. Coarse Grinding and Coatings Removal
- 16 Grit Single (Quick Release) Soft Bond
- 16 Grit Double (Quick Release) Soft Bond
4. Grit Levels for Concrete Hardness
- 30 Grit Single (Quick Release) Soft, Medium, and Hard Bond options
- Double (Quick Release) options also available
5. Light Grinding/Scratch Removal
- 70 Grit Double (Quick Release) Medium Bond
- 120 Grit Double (Quick Release) Medium Bond
6. Hybrid Grits and Resin Bond Options
- Hybrid Grits: 50, 100, 200
- Resin Bond: 200, 400, 800, 1500, 3000
7. Quick Release Diamond Plates
- 3 Segment Set for Trelawny TPG Floor Grinders
- 6 Segment Plate for Trelawny TCG Floor Grinders
8. Polishing Plates
About the company:
Trelawny SPT Ltd., based in the United Kingdom,is one of the leading manufacturers of floor surface preparation equipment. Manufactured with superior materials and powered by reliable components, their equipment and tools are designed for the most demanding conditions. The company’s equipment and tool applications include floor grinding, scabbling, levelling, texturing & cleaning. Their products have been tried and tested around the world on Metro Stations, Stadiums, Airports and Bridges etc.
To enhance customer accessibility, the company has strategically established a robust distributor network with stock points in major cities. This ensures swift and efficient service for customers, supported not only by Company Technicians but also by Distributor technicians. The company also ensures that sufficient stock of machines, tools and consumables are available all the time.
Contact:
Trelawny SPT India
Mumbai/Pune, India
Ph.No: +91 9881745485
Email: vishram.kanetkar@trelawny.co.uk
Website: www.trelawnyspt.com