sk ten different architecture,

design, building, or specifica-

tion professionals what

“green” means with regard

to building materials and

finishes, and there’s a

good chance you’ll get

ten different answers.

The same goes with manufacturers of

products used in design and construction:

• Low VOCs

• Non-toxic (non-HAPs) content

• Sustainability (itself the subject of con-

siderable variation in interpretation of the

term’s meaning)

• Performance/durability

• Long service life

• Low carbon footprint

• Favorable lifecycle implications

So what is the building professional

to do? Try to balance the various criteria?

Focus on the environmental friendliness

of materials? Give precedence to perfor-

mance, durability, and service life? Follow

the supply chain and seek out the lifecy-

cle champion?

In this report, JAC seeks to shed some

light on this current quandary, while

focusing on one specific aspect of the

building—the concrete floor. We won’t

presume to arrive at an ironclad, defini-

tive conclusion on “What Green Means”

with regard to concrete floor coatings and

treatments, but we will at least examine

some of the important factors that might

be weighed in assessing the various tech-

nologies used to protect, color, and deco-

rate these increasingly important surfaces.

Concrete: Inherently green?In the view of many in the building and

design community, floors of concrete left

exposed (no floor covering on top) enjoy

a natural advantage in the green- and sus-

tainable-building hierarchy. Concrete, this

thinking goes, is inherently durable, long-

lasting, and hard wearing. Minus a cover-

ing on top such as tile, carpet, or sheet

flooring, the concrete floor—whether

stained, polished, coated, or integrally

colored—generates little or no waste

thanks to the lack of a need for periodic

replacement.

The manufacture of concrete also can

make use of industrial byproducts such as

fly ash from coal combustion, and con-

crete can itself be recycled and reused as

aggregrate in new concrete, as backfill, or

12 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008

The definition

of sustainability

carries range

of implications

for floor coatings

and treatments

By Joe Maty, Editor, JAC

Awhatever that meansGoing green,

Photo courtesy of Crown Polymers

Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008 13

as road base. In addition, the primary

ingredients in concrete—cement, sand,

and aggregrate—typically originate from

the local or regional area of the ultimate

end use, meeting another sustainability

objective due to reduced transportation

needs.

If concrete does, indeed, merit at least

some credit as a sustainable building

material for these reasons, the question

facing the green-minded specifier, design-

er, or owner then becomes, how can the

concrete floor be altered or treated to

meet design objectives while maximizing

aesthetic and performance aspects of the

floor?

In search of answers, JAC in this issue is

launching into a discussion of “What

Green Means” with regard to concrete

treatments and coatings, focusing on the

various types of materials and processes

involved in protecting and decorating the

concrete-floor surface. In addition, we

will attempt to enlist the expertise of

authorities in the sustainable building

and design community to gain a greater

understanding of the meaning of green

in this context of the concrete floor.

Concrete polishinggets positive ‘green’ reviews

The concrete-polishing process, in which

special chemical “hardeners” or “densi-

fiers” are applied to a machine-prepared

concrete-floor surface, is receiving posi-

tive reviews in terms of its contribution

to sustainable design. The technology is a

relatively recent development, having

made its debut in the 1990s.

The process starts with the “opening

up” of the concrete surface with grinding

machines using diamond-impregnated

discs, followed by application of a hard-

ener/densifier formulation, which reacts

with the concrete. The job is completed

with additional grinding and polishing,

the optional addition of color with stains

or dyes, application of a sealer, and bur-

nishing to achieve a glossy surface.

In the wet-polishing process, applica-

tion of the hardener/densifier is followed

with wet vacuuming. For the dry-grind-

ing process, which employs a lithium sili-

cate hardener, little or no cleanup is

required. Different color approaches can

be used with polishing, including integral

coloring of the concrete mixture (in the

case of new installations) or application

of stains or dyes to the densified con-

crete. A clear topcoat or sealer is also

applied in many cases, and a final touch

is polishing with a high-speed burnisher.

Dwayne Fuhlhage, regulatory affairs

director for PROSOCO Inc. and a certified

hazardous materials manager, says his

company’s polished-concrete materials

offer a combination of low VOC content

and functionality that contributes to the

floor’s durability, appearance, and perfor-

mance—translation: a positive sustain-

ability profile.

PROSOCO’S entry in the concrete-pol-

ishing marketplace—the Consolideck

process—is built around the use of lithi-

um silicate hardeners, which Fuhlhage

says accomplish the hardening and den-

sification of concrete with essentially no

waste generation. The lithium silicate

hardener/densifier is applied to the pre-

pared concrete surface and allowed to

“dwell” for 15 to 20 minutes, penetrating

Photo on facing page and at right and below: Makers of concrete coatings, stains, concrete-polymer overlays, and other treatments havemade strides in greening their product offerings with waterborne, 100% solids, and zero- and low-VOC technologies while seeking to

retain or enhance sustainability as defined by performance and durability.

Photo courtesy of Crown Polymers

Photo courtesy of Richard James Specialty Chemicals

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the concrete surface. The densification

reaction occurs quickly and completely,

leaving no residue for cleanup, he says.

Fuhlhage says polished concrete com-

pares favorably to other flooring materi-

als in sustainability terms, citing as an

example the use of linoleum. While

linoleum is thought of as being “green”

due to the renewable nature of its com-

ponents, Fuhlhage points out that the

supply chain carries a lengthy geographic

reach—as far as the Pacific Rim region for

jute, and the Mediterranean area for cork.

Fuhlhage says PROSOCO emphasizes

that concrete and masonry are sustain-

able substrates, but only with proper

maintenance and care.

Paul Grahovac, a LEED accredited pro-

fessional (AP) with PROSOCO, says pol-

ished concrete floors do require ongoing

maintenance, but he says this aspect of

the technology is relatively simple, with

application of a special cleaning formula

that includes a small amount of the hard-

ener/densifier product. The cleaner can

be applied by mop or with a floor-clean-

ing machine or sprayer. The cleaner actu-

ally reinforces the densification effect, he

says.

L.M. Scofield Company, another player

in the concrete-treatment field, offers all

three of the major types of hardener/den-

sifier chemistries: lithium silicate, sodium

silicate, and potassium silicate. Cam

14 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008

Makers of concrete coatings, stains, overlays, and othertreatments—companies such as Sherwin-Williams, CrownPolymers, Richard James Specialty Chemicals, andmany others—can make a strong case that they havemade great strides in greening their product offeringswhile seeking to retain or enhance sustainability asdefined by performance and durability.

The following is a sampling of some of these tech-nologies. These are only representative examples ofproduct offerings for concrete floors; this category ofproducts is varied and extensive.

Butterfield Color Inc.•Renovatio™Opaque Concrete Stain, a polymerized(non-acid) stain that penetrates and bonds with theporous concrete substrate•Renovatio Translucent Accent Stain•Elements Transparent Water-Based Stain, a nanopig-ment non-acid stain that penetrates the concrete sub-strate to create translucent color variations similar toreactive acid stains

Crown PolymersThe company’ s tagline, “All Our Colors are Green,” isa reference to a zero-VOC, 100% solids product line ofepoxy and polyurea coating and terrazzo systems. Theproduct line includes the following.•Polymer overlay, decorative-floor overlay, and epoxy

terrazzo systems Crownspatter™, CrownHybrid™,CrownQuartz™, CrownImage™, CrownStone™, CrownAccent™,CrownFlake™, CrownChips™, CrownShield™, Crown NaturalStone™, Crown Thin-Set Epoxy Terrazzo™•Epoxy, polyurea, and polyurethane topcoats CrownClear™and CrownPro™

GoldenLook of Texas•GoldenLook Epoxy Stone System 100% solids epoxyaggregate resurfacing system

Key Resin Company•Key Quartz B-65 and B-125 100% solids epoxy/coloredaggregrate decorative resin flooring•Key Epoxy Terrazzo 100% solids decorative epoxy/aggre-grate flooring

L&M Industries LLC•Sim Stain waterborne simulated acid stain concrete stain

Quality Systems Inc.•PermaCrete®waterborne bag mixes, sealers, epoxies,urethanes, cleaners, and crack-repair products

Richard James Specialty Chemicals Corp.•StoneClean™Concentrates, formulations for cleaning,maintaining, or stripping sealed and unsealed stone, tile,brick, concrete, and cementitious surfaces

New shades of green

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Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008 15

Villar, the company’s director of market-

ing, calls the lithium-silicate technology a

“top of the line, true architectural-level

densifier.”

But manufacturers of the densifier

products aren’t alone in touting the

green/sustainable merits of the concrete-

polishing technology. Alex Wilson, exec-

utive director of BuildingGreen.com, has

given the technology a ringing endorse-

ment. BuildingGreen.com is an influen-

tial voice in the green-building commu-

nity, and is an independent publishing

company that researches and reports on

green design and building methods and

materials. The company publishes

Environmental Building News and the

GreenSpec Directory, and offers the

BuildingGreen Suite of products to its

subscriber members.

In an article published in Environ-

mental Building News in 2006, Wilson

concluded that polished, densified con-

crete constitutes a “significantly better

alternative” to coatings and waxes, in

large part due to the relative permanence

of the densified and polished concrete

surface.

Wilson gives the densifying/polishing

technology sustainability points for

durability, UV resistance, ease of main-

tenance, and the concrete floor’s “struc-

ture as finish” condition, with no over-

lay, topping, or additional floor cover-

•StoneLok™water-dilutable polyurethane floor coatingand StoneLok MLT Plus waterborne penetratingpolyurethane sealer•TekSeal™PRO One-Pack fast-dry waterborneprimer/sealer

Smith Paint Products•Smith’ s Color Floor waterborne acrylic decorative stain•Smith’ s Green Clean, a noncorrosive acid cleaner forconcrete•Smith’ s Base Boost, a silicate-based, no-VOC liquid for-mulated to densify or fortify the concrete floor; can beadded to the coating product to enhance the chemicalbond with the substrate

PPG Industries Inc.PPG offers MegaSeal Green, a comprehensive industrialflooring product line that includes products for light-dutycommercial to institutional to heavy industrial environ-ments. The coatings products—primer/sealers, topcoats,self-leveling coatings, high-performance urethanes, andepoxy repair materials—include•100% solids, zero-VOC epoxy coatings and repairmaterials;•zero-VOC waterborne epoxies;•low-VOC epoxies; and•high-solids, low-VOC urethanes.

The Sherwin-Williams Company, General Polymers®The company offers an extensive range of seamless

flooring systems, terrazzo, coatings, and repair productsfor commercial, institutional, and industrial applica-tions, all with VOC levels of 100 grams per liter or less.Major products for commercial and institutional usesinclude the following.•Thin-Set Epoxy Terrazzo #1100•FasTop urethane cement floor topping•Ceramic Carpet epoxy quartz floor topping•Epo-Flex systems flexible epoxy membranes

Vexcon Chemicals Inc.StarSeal EF (Eco-Friendly) products (low odor, low VOC)•StarSeal EF acrylic coatings and stains•StarSeal EF Primer and Starseal EF Epoxy•StarSeal PS Systems hardeners and densifiers•StarSeal EF protective treatments: EF Weather Seal, EFWaterproof, and EF Weather & Stain Guard•StarSeal EF Degreaser and Cleaner, StarSeal EFStripper

Westcoat•EC-31 Clear Epoxy Topcoat, 100% solids, zero-VOCclear topcoat or binder•SC-41 Water-Based Sealer, hybrid acrylic/urethaneclear concrete sealer and glaze, under 100 grams perliter VOCs•SC-70 Stone Glaze, acrylic lacquer sealer, formulatedwith non-VOC solvents•SC-35 Water-Based Stain, water-based with low toxicity

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16 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008

ing required. This provides economies

and reduces raw-materials consump-

tion and environmental impacts, he

says. Also a plus are the negligible or

nonexistent VOC emissions from the

products used, meaning indoor air

quality is not adversely affected.

Other positives, Wilson says, are resis-

tance to staining from spills due to the

reduced porosity of the densified con-

crete; absence of flammables; and

increased reflectivity, resulting in the

potential for reduced need for lighting.

The thermal mass of the concrete also

enhances passive solar heating and night

“flushing” for cooling effect, he adds.

As with other technologies, however,

Wilson observes that polished concrete

isn’t without its limitations. The

acoustics may be bouncy, and the ther-

mal conductivity of concrete can result

in cool-season chill.

In summary, Wilson predicted that,

with its advantages, polished, densified

concrete floors “will become the flooring

option of choice for hard-surface flooring

in schools, retail stores, industrial build-

ings, and a wide range of other commer-

cial buildings.” He also forecast growth

in applications in residential settings.

Building on the polishing portfolioPerhaps sensing that concrete polishing

is gaining momentum in the design and

building community, manufacturers are

looking to develop technologies that

can play a part in this growth industry.

An example: a formulated water repel-

lent developed by Dow Corning Corp.

that is marketed as a means to fortify

the resistance capabilities of the pol-

ished concrete floor.

The repellent product, carrying the

name Dow Corning IE 6694, is a low-

VOC, dilutable silane/siloxane blend,

says David Selley, technical service spe-

The concrete-polishing process, in which special chemical harden-ers, or densifiers, are applied to a machine-prepared concrete-floor surface, has received positive reviews as a sustainable-

design technology. Photo courtesy of PROSOCO Inc.

cialist with Dow Corning’s Building Materials Protection

Group.

Selley says the silane/siliconate chemistry is designed to fur-

ther reduce the porosity and boost the water repellence of the

densified and polished concrete surface, enhancing resistance

to oil, grease, and other stain-causing agents.

Can anything brake the polishing express?But before the concrete densifying/polishing express leaves all

other concrete treatment and coating systems in its wake,

developers and manufacturers of these more traditional tech-

nologies may raise a cautionary flag. Issues that should get

consideration when deciding on the correct concrete-floor

treatment approach, these manufacturers say, include the

severity of the service environment, the importance of uni-

form color and color matching, slip resistance, and the techni-

cal challenge of getting the desired result with the relatively

labor-intensive densification/polishing process.

Bruce Maier, chief scientist of coatings manufacturer

Richard James Specialty Chemicals, says “grind and shine”—

his term for the concrete densification/polishing process—“as

a general rule, is extraordinarily energy and labor intensive if

you’re trying to get dense colors.

“Grind and shine is an art form, and variation is an issue,”

Maier says.

Richard James Specialty Chemicals is a manufacturer of low-

VOC, waterborne concrete-floor coatings based on epoxy, ure-

thane, and acrylic chemistries. The company also offers inte-

gral colors for concrete. Maier says the company has sought to

create advanced materials that offer a range of color and effect

Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008 17

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Design and color techniques involving the concrete densification/polishing process include the useof integral coloring of the concrete mixture (in the case of new installations) or application of

stains or dyes to the densified concrete. Photo courtesy of PROSOCO Inc.

JAC

18 Jou r na l o f A rch i t ec tu ra l Coa t i ng s / Oc tobe r / Novembe r 2008

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features, are highly impact and chemical resistant, and are

characterized by a high degree of adhesion to the substrate

facilitated by a proprietary organosilane component.

“Where you want to get the job done fast and you don’t

have a lot of time—those are the situations where grind-and-

shine systems aren’t applicable,” Maier says. He cites as exam-

ple the floor of a retail sporting-goods store where one of his

company’s products was used. The client wanted the entrance

to the ski area of the store to be a specific ice-blue shade, with

a durable, anti-skid surface. In this case, a coating fit the bill.

Lonnie Salyers, vice president, technical operations, for The

Sherwin-Williams Company’s General Polymers brand of floor

coatings and systems, says high-performance urethane and

epoxy coatings offer the performance needed “anywhere

where chemical resistance and physical-abuse requirements

are factors.” These types of resinous systems offer resistance to

impact and chemical agents ranging from food and beverage

stains to harsh chemicals and oils.

Floyd Dimmick, technical director of Crown Polymers, also

a manufacturer of floor-coating and polymeric overlay sys-

tems, echoes Maier’s assessment of factors that may limit the

applicability of concrete densification/polishing. “It takes mul-

tiple polishings to get the desired result,” he says. “Also,

defects or weakness in concrete are an issue with polishing,

where you have pitting and degradation. You can deal with

this with overlays.

“We get a lot of partially finished polishing jobs,” Dimmick

says, referring to densification/polishing projects that went

awry or otherwise didn’t pan out. He contends that a high-

performance epoxy polymer concrete can match or surpass

densified/polished concrete in durability and service life.

“That is sustainability,” he says. “Concrete polishing has

found a market in high-end settings, such as shopping malls,

retail stores—where the look is the selling point.”

Although his company makes densifiers for concrete polish-

ing, Cam Villar of L.M. Scofield agrees that the polishing

process isn’t meant for every concrete floor project. “Polishing

is more labor intensive,” he says. The condition and age of

existing concrete floors also dictate whether the surface can be

brought up to a condition that will meet the performance and

appearance objectives of a polishing project.

L.M. Scofield also manufactures concrete stains and integral

coloring, which can be used to color and decorate concrete

with or without employing the densification/polishing

process.

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