We are building a 18′ x 28′ cottage with a concrete slab that we plan to stain and seal. Yesterday we had a professional cutter score it with 2′ x 3′ “tiles”. The cuts are 3/16″ wide and 3/8″ deep. When he was finished, the cutter said that the concrete had spalted “a little.” It looks terrible! The top edges of the cuts are jagged and ragged. The contractor said it would be “fine” when it was grouted and sealed. I do not see how grout could fill in the sharp nicks and chips that extend onto the top of the slab. In any case, the damage is done. The best I can do at this point, I think, would be to smooth off the sharp edges and perhaps blend in the worst of the chips. It might never look great, but at least it will be smooth enough to walk on without shoes. I am willing and able to spend the necessary time and energy to correct the problem. Someone suggested I could use a 4″ grinder. What is this and how would it work? Any other suggestions would be appreciated.
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Replies
why not cover it up?
With hydronic radiant heat, this is not an option.
You may not wish too but carpet, engineered flooring like Pergo are all ok over radiant. And, not being a concrete guy there might be a trowel down product available. Sounds like they cut it too late. DanT
Sounds like a dry cut with a diamond blade on a green slab. A coulpe of things can cause the excessive chipping. The first being a d-blade at the end of its' life. The second is a worn out POS saw, that has to much run out on the spindle arbor.
Can you post some pictures?
hard to offer advice w/o seeing how bad it is.
Dave
It was not a dry cut, but it was on a slab poured five days earlier. I don't have pictures because the slab is now covered for protection during construction. What do you think about using a 4" grinder?
Depending on how deep it is you could potential have it ground out. Something that big and that you need to look right has to be done with specialized machines that would resurface the whole floor. But it would also change the character as it would show ground stones. You could accept it as part of the character of stained concrete floor.You could have a topping mix put over it.The is an article in JLC sometimes last year where a contractor uses special selfleveling mixes to put thin coats on concrete or even wood floors so give a fresh surface for staining and stamping.You could install wood, carpet, tile, or almost anyother covering as a finished surface. Now some adjustments in the water temp might need to be made.