TKO Concrete Coatings Tackles 100,000 sq ft Factory Floor Grinding with Propane-Powered Precision

When a large manufacturing client needed over 100,000 square feet of factory floor prepped for a high-performance urethane cement flooring system, they called TKO Concrete Coatings. Our video of the project highlights the power and efficiency of our 32-inch planetary propane walk-behind grinders, showcasing why propane-driven concrete grinding is the gold standard for indoor and semi-enclosed industrial jobs.

Why Proper Grinding Is Essential

Before installing any urethane cement or industrial coating, achieving the correct Concrete Surface Profile (CSP) is critical. Grinding:

Removes old coatings, adhesives, and laitance, exposing the strongest layer of substrate.
Levels high spots and trowel marks, ensuring a flat, uniform surface.
Opens micro-pores so that urethane cement bonds mechanically to the concrete, preventing delamination or premature failure.

By grinding the entire 100,000 sq ft slab, TKO guarantees that the forthcoming urethane cement system delivers its full compressive strength, chemical resistance, and longevity.

The Power of 32″ Planetary Propane Grinders

1. Massive Coverage & Fast Material Removal

Our 32-inch planetary grinders feature multiple rotating heads that spin on a central plate—dramatically increasing surface contact and grinding speed. This machinery:

Preps vast areas quickly, helping us complete large-scale floors in days rather than weeks.
Handles aggressive removal of concrete surface flaws, old coatings, and minor spalls with precision.

2. Propane’s Low-Emission Advantage

Indoor or semi-enclosed factory spaces pose unique health and safety challenges. Unlike gasoline or diesel machines, propane-powered grinders produce significantly lower carbon monoxide and particulate emissions. This ensures:

A safer work environment for our crew, reducing the risk of respiratory irritation or toxic exposure.
Compliance with OSHA indoor air quality guidelines and local environmental regulations.

3. Cord-Free Operation for Maximum Flexibility

Electric grinders require constant access to power outlets—often hundreds of feet apart in sprawling factories. Propane units free us from extension cords, enabling:

Uninterrupted grinding across large open spaces without tripping hazards or power drops.
Enhanced maneuverability around machinery, racking systems, and production lines.

TKO’s Grinding Process in Action

Site Assessment & Mobilization
- We begin by evaluating the existing slab’s condition, moisture levels, and any obstacles. Our team stages the propane cylinders and grinders to optimize workflow and minimize downtime for the client.
Rough Grinding (CSP 2–3)
- Using 30- and 60-grit diamond tooling on the planetary grinders, we remove surface contaminants and establish the initial profile needed for urethane cement adhesion.
Crack Repair & Leveling
- High spots are ground down, and any cracks or spalls are addressed with high-strength epoxy patching compounds. This step ensures a perfectly level plane.
Fine Grinding & Edge Work
- Switching to finer grits (100–200), we smooth transitions, feather into existing lines, and prepare edges for a seamless coating application.
Final Cleanup
- Our integrated dust-control vacuums capture over 95% of airborne concrete dust, leaving a clean, ready-to-coat surface.

Preparing for Urethane Cement Installation

With the grinding complete, the floor is now primed for the urethane cement mortar that will follow. This industrial‐grade system offers:

Compressive strengths up to 6,000 PSI, ideal for heavy machinery and forklift traffic.
Thermal shock resistance, perfect for areas subjected to steam cleaning and temperature fluctuations.
Chemical and abrasion resistance, protecting against spills, detergents, and mechanical wear.

Thanks to our meticulous grinding, the urethane cement will bond flawlessly—delivering a seamless, non-porous, USDA-compliant food and beverage environment for clients in sectors ranging from manufacturing to food processing.

Why TKO Concrete Coatings Is Your Go-To for Industrial Grinding

Industry-Leading Equipment: We invest in the latest planetary grinders and diamond tooling to tackle projects of any size.
Propane Expertise: Our technicians are trained and certified in safe propane handling and indoor emissions management.
Turnkey Service: From grinding and repairs to urethane cement installation, TKO provides end-to-end solutions—saving you time and coordination headaches.
Safety & Compliance: We adhere to stringent OSHA and EPA standards, ensuring your facility remains operational and compliant throughout the project.

Ready to see your facility transformed? Watch our grinding crew in action and discover why propane-powered precision is the smart choice for industrial floor prep. Contact TKO Concrete Coatings at 615-414-3727 or visit www.tkoconcrete.com to schedule a free assessment—and take the first step toward a flawless urethane cement floor.