Before getting into the details of Comins’ success, here are a few details about how Diamatic’s ULTRAFLOR Architectural Polished Concrete Systems, designed to produce an extremely hardened, dust-proofed, reflective surface that imparts chemical, abrasion and stain resistance to concrete floors; and the science behind the product.
ULTRAFLOR is a system of products engineered to work together. By taking high quality diamond tooling polishing equipment, lithium chemistry for densifying and guard products, repair materials, pinhole filler, and even a water based dye; training and specification support make it a single source solution.
“The science is in the lithium technology combined with a specified process that has been proven to produce results consistently over the past eight years all over the U.S., Europe and Asia,” states Clark Branum, Diamatic’s ULTRAFLOR program manager.
Since the product is designed to convert ordinary concrete into highly decorative, quality floor surfaces suited for high-end retail, commercial, institutional and architectural applications, it can also be used in environments exposed to grit, salt, oil and other solvents.
“Standard ASTM stain testing has been done for all the products in the system,” Branum says. “We have guard products that meet specific levels of protection based on the floor or project requirements. We also have a cross-linked densifier that will prevent salt intrusion into the concrete surface in areas where deicing slats are commonly used. The ULTRAFLOR system can be used on any interior concrete floor.”
As for older concrete floors with cracks and other surface defects, Branum says the system has a repair component that includes a polishable repair product and pin hole filler designed to repair any surface defect regardless of the size or shape. Crack repair, on the other hand, is better handled using a joint material that can be matched to the floor and respond to movement that is common in a structural crack.
For customers, the system is designed to reduce overall life cycle costs and maintenance requirements. The system is based on producing full surface refinement. By following a step-by-step process that results in a better gloss retention, higher distinctness of image, stain and wear resistance, the finished polishing results will last much longer than other techniques. Following a maintenance specification will extend the life cycle of an ULTRAFLOR project beyond 15 years according to Branum.
Green Polishing Solutions
Now, back to Comins and his Green Polishing Solutions’ business which he’s built primarily through the success he’s achieved using the ULTRAFLOR system.
“We’ve been working with the product for the past eight years and today 90 percent of our polishing business is with the ULTRAFLOR system,” Comins notes. “The industry has evolved over the years with better machinery and chemicals introduced to achieve high-quality polishing results; and the chemical concrete solutions are what have elevated the results we’re seeing out in the market. I believe Diamatic equipment is the best on the market; and the combination of equipment and chemicals are helping us achieve the results we’re able to deliver to our customers.”
The lithium-based densifiers and sealers are clearly the game changer for Comins when it comes to delivering a dust-free, shiny and durable finish.
On an existing concrete floor, Comins’ crew begins preparing the surface with a series of grinding grits – 16/20, 30/40, 60/80, 100 and 200 before applying the Diamatic ULTRAFLOR Flor-Sil lithium densifier, which is then followed by a 400, 800, 1,500 and 3,000 grit resin or plastic polishing pads. Finally, a 27-inch 3,000 grit burnishing pad and Diamatic ULTRAFLOR Flor Finish are used to seal the surface.
“I’ve done research comparing sodium and potassium silicate densifiers with lithium silicate densifiers and the lithium delivers a clearer shine that really pops, and one that retains that shine and durability longer than conventional densifiers,” Comins says.
Even in applications where controlled joints and surface issues had to be repaired with a cementitious product, the lithium densifier/sealer penetrates deeply, resulting in exceptional clarity across the entire surface.
With the array of products that complete the ULTRAFLOR system, from pinhole/void filler to color dyes to densifier to stain resistance to wear protection to film buildup to cleaning, Comins says he’s able to deliver a long-lasting solution that meets his customers’ expectations.
With 80 percent of his polishing business tied to refurbishing existing concrete and 20 percent on new concrete his crews have poured, Comins expects the polishing business to only continue its upward trajectory. Early in his flooring career, Comins installed lots of carpeting, vinyl and laminate flooring over concrete. That all switched about a decade ago when he saw the light, the reflective bright light of highly polished concrete and began offering customers a sustainable way of maintaining a good-looking and durable floor. Because of its thermal qualities, it can be used to cut energy costs. Polishing to a high sheen also lowers energy costs by reflecting all light sources. Properly maintained, there’s no need to replace a polished concrete floor, unlike other floor coverings.
Whether it’s a 500 sq.-ft. or 100,000 sq.-ft. job, Comins is equipped to quickly mobilize and turn an old gray concrete slab into a decorative architectural focal point. From retail centers to condominium lobbies to high school common areas, Comins says, “Once you leave the place, everyone is high fiving over the final results. And then it’s simply a matter of proper cleaning to maintain that just-finished look.”
