Common Concrete Issues and How Contractors Can Address Them

Concrete is one of the most durable and widely used building materials in the construction industry. It’s versatile, strong, and relatively low-maintenance compared to other materials. However, even concrete isn’t impervious to wear and tear or the challenges of natural elements over time. From cracks to discoloration, these issues can quickly compromise structural integrity or aesthetic appeal if left unresolved.

Proper procedures and materials during concrete installations are crucial to prevent these issues from arising. For contractors, addressing these common concrete problems isn’t just about maintaining quality—it’s about delivering results efficiently and effectively. This blog will explore some of the most common concrete issues, how contractors can solve them, and why Onfloor concrete grinders are essential in any professional’s arsenal.

Common Concrete Issues

1. Structural Cracks

Cracked concrete is one of the most prevalent issues in concrete structures. It can be caused by several factors, including shrinkage during the curing process, thermal expansion, and contraction, or uneven settling of the ground beneath the slab. While small hairline cracks might be cosmetic, larger cracks may compromise the structural integrity of the surface.

Solution

Crack repair requires a combination of filling and surface preparation. Onfloor concrete grinders make this task significantly easier by efficiently leveling uneven surfaces around the crack and preparing them for repair materials like epoxy or sealants. Even better, our quick-change tooling feature allows contractors to switch between attachments seamlessly from grinding to polishing, saving time while ensuring a flawless finish.

Extra Tips on Addressing Cracking

• First, gauge the crack's severity and determine if it requires professional attention.
• Always follow manufacturer instructions for repair materials and drying times.

2. Concrete Flaking

Spalling, also known as concrete flaking, occurs when the surface of the concrete flakes or chips away, revealing a rough and uneven texture. This typically happens due to freeze-thaw cycles, poor finishing techniques, or the use of low-quality materials. Spalling can weaken the surface and detract from the appearance of the structure.

Solution

Spalled areas must be ground down to remove loose chunks and create a smooth, durable surface. Onfloor’s multi-speed concrete grinders, such as the OF20Pro, are equipped to handle spalled surfaces effectively. Our grinders’ ergonomic lightweight design enables contractors to work comfortably for extended periods without fatigue.

Extra Tips on Addressing Spalling

• Inspect surrounding surfaces for signs of spalling and address them preemptively to prevent further damage.
• Use a dust collection system to minimize clean-up time and reduce the risk of inhaling harmful particles.

3. Concrete Discoloration

Improper concrete mix proportions can lead to discoloration, as inconsistent curing and exposure to pollutants affect the final appearance. Discolored concrete can make walkways, garages, and floors look unsightly, even if they remain structurally sound.

Solution

Aside from ensuring a proper concrete mix from the start- polishing is the go-to method for correcting discoloration and restoring the uniform appearance of concrete. With Onfloor concrete grinders, contractors can achieve a polished finish that highlights the material's natural beauty. Our patented triple-belt system ensures even contact and smooth movement across the surface, providing consistent results every time.

Extra Tips on Addressing Discoloration

• Clean the surface thoroughly before polishing to remove any grime or debris that may affect the final appearance.
• After polishing, use a densifier to enhance the color and protect against future discoloration.

4. Surface Imperfections

Bumps, ridges, and other surface irregularities are common in concrete surface applications, especially when proper leveling or screeding techniques haven’t been used. Left unaddressed, these imperfections can affect safety and usability.

Solution

Our machines, like the OF9S-L, are designed to tackle surface imperfections with precision. Lightweight yet powerful, some models are compact enough to fit in the back of an SUV, making them ideal for projects of all sizes.

Extra Tips on Addressing Surface Imperfections

• Regularly inspect surfaces for imperfections and use a grinder to correct them before they become problematic.
• Understand where the surface imperfections come from. That way, you can address the root cause

5. Coating or Adhesive Residue

Concrete surfaces that previously had coatings, adhesives, or sealants often require thorough removal before new applications can be applied. The residue left behind can hinder the adhesion of new coatings, leading to premature failure.

Solution

Onfloor grinders excel in coating and adhesive removal. Their quick-change tooling allows contractors to switch from grinding to stripping tools effortlessly, while dust collection features help maintain a clean and safe work environment. These machines ensure thorough removal, leaving the surface ready for the next stage of treatment.

Extra Tips on Addressing Coating or Adhesive Residue

• Identify the type of residue to be removed and use the appropriate tooling for efficient removal.
• Use a vacuum attachment on the grinder to collect dust and debris as it is being removed, reducing clean-up time.

6. Efflorescence

Efflorescence is a chalky white residue that appears on the surface of concrete due to moisture migration. Efflorescence can also be influenced by the fill material supporting the concrete, as moisture migration from the fill material can lead to the appearance of chalky white residue. 

While it’s not harmful to the structure, it detracts from the appearance of the surface and can be difficult to remove.

Solution

Grinding and cleaning the affected areas is the most effective way to eliminate efflorescence. Onfloor machines are designed to handle delicate and heavy-duty tasks, making them versatile tools for such situations.

Extra Tips on Addressing Efflorescence

• Clear water repellents, along with silicone and acrylic coatings, can also assist in removing efflorescence effectively.
• Keep masonry materials elevated and shielded with waterproof sheeting to protect them from absorbing unnecessary moisture or salts.

7. Broken or Uneven Concrete Slabs

Broken or uneven concrete slabs can be a significant issue for property owners, as they can lead to tripping hazards, water accumulation, and further damage to the surrounding concrete structure. These problems often arise due to settlement, soil compaction, or poor construction practices.

Solution

Broken and uneven slabs need to be evaluated to determine the severity of the problem. If it's a surface-level problem, then grinding is probably the way to go—however, if it's more deep-rooted, you might have to replace the entire concrete slab.

Extra Tips on Addressing Broken or Uneven Concrete Slabs

• Always assess the root cause of the problem before proceeding with repairs.
• Use Onfloor grinders to level the surface and prepare it for patching or replacement.
• Consult with a professional in the construction industry to ensure the structural integrity of the building is not compromised.
• Regularly inspect concrete slabs for early signs of damage to prevent more extensive repairs in the future.

How Onfloor Concrete Grinders Empower Contractors

Onfloor concrete grinders not only help address common concrete issues but also elevate the efficiency and quality of work with the following standout features:

Patented Quick-Change Tooling

One of the contractors' biggest challenges is switching between tools for different tasks. Onfloor has solved this with its patented quick-change tooling system, allowing users to transition seamlessly between grinding, polishing, and coating removal tools in seconds.

Ergonomic Design

Long hours on the job can wear on contractors. That’s why Onfloor grinders are ergonomically designed for comfort and ease of use. Some models are lightweight and portable, even compact enough to fit in the back of an SUV, making transportation to job sites easy.

Triple-Belt System

The triple-belt system in Onfloor grinders ensures consistent, smooth performance, reduces vibrations, and delivers exceptional results across varied surfaces.

Versatile Applications

From crack repair to polishing, spall removal, and coating preparation, Onfloor grinders are built for multi-surface applications, ensuring contractors can meet the diverse demands of their clients with one machine.

Additional Things to Consider

As versatile and effective as Onfloor grinders may be, contractors still face some common challenges when grinding concrete surfaces.

These include:

• Dust control: The dust produced during the grinding process can be hazardous to workers' health and cause problems for surrounding areas. Proper dust control measures must be in place to ensure safety and avoid causing a mess.
• Hard-to-reach areas: Some spaces, such as corners or edges, may be tricky to reach with larger grinders. Specialized tools or hand-held grinders may be needed for these areas.
• Curved surfaces: Traditional flat grinding machines are not suitable for curved surfaces, making it difficult to achieve a smooth and consistent finish in these areas.
• Uneven surfaces: Uneven concrete surfaces can be challenging to grind, as they require extra care and precision to level out. This can be time-consuming and may require multiple passes with different tools.

Conclusion

Concrete is a durable and versatile material, but it can face challenges that require immediate attention. From cracks and spalling to efflorescence and uneven slabs, these issues not only affect the appearance of concrete but also its structural integrity. 

Yet fear not- with the right tools and techniques, these problems can be addressed effectively.

Onfloor concrete grinders allow contractors to tackle common concrete problems quickly and efficiently. With features like quick-change tooling, ergonomic designs, and powerful performance, our grinders are built to make job sites more manageable and deliver exceptional results.