The Jeffco crew was on the project for eight weeks. Five crew members equipped with three planetary grinders performed the polishing and joint work while two additional crew members performed the template and dye application for the artwork.
The crews worked the floor in phases, starting first by cutting the decorative saw cuts and placing a clear polyurea joint filler in all joints. They used clear joint filler so it would pick up the appropriate color during the dye process.
McCool says the concrete was in good shape for polishing. The grinding/polishing crew started grinding most of the floors with an 80 grit metal abrasive; in a few areas they started with 40s. From the 80 grit metals, Jeffco crew members moved to a hybrid diamond in lieu of a 150 grit metal abrasive.
After the hybrid step, crews applied the first application of densifier. From there they proceeded through typical resin bond abrasives steps, starting at 100, moving to 200, then to 400. The dye process took place after the 400 grit abrasives. It was a little more involved than a typical job because of the artwork and the number of dyes specified throughout the floors. The architect chose 20 different dye shades from three different manufacturers. The construction plans for the project were very detailed, which helped Jeffco’s crews ensure they were using the right dye in the right spot.
For each piece of animal, vegetable or map artwork, the Jeffco crew placed a blank vinyl template where each illustration would be. Then it applied the main surface dyes and densifier. After the detail crew went through and colored in the artwork, the animals and other illustrations got their own shot of densifier. That process was followed up with an 800-grit resin pass, guard and burnish on the entire floor. The two Jeffco crews moved throughout the school in this manner until they completed all sections of the project.
McCool says all parties involved with the project were happy with the results. The school district will enjoy lower maintenance costs and students will gain inspiration with every step.
Polishing Contractor: Jeffco Concrete Contractors, Tuscaloosa, Ala., President Jeff McCool, www.jeffcoconcrete.com
Architect: Ward Scott Architecture
Interior Designer: Interior Design Professionals, Inc.
Construction Manager: WAR Construction, Inc.
Scope of Project: Polish 49,000+ square feet of floors and install 50+ illustrations on those floors throughout a school.
Key Products and Equipment: HTC 800 grinder; SASE PDG 8000 grinder; SASE tooling; Prosoco densifier and guard; dyes from Scofield, Prosoco and Ameripolish; Hi-Tech Systems polyurea.