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Polished concrete in cold storage sits between freezer air, chiller humidity and constant forklift traffic, so substrate moisture, insulation interface, freeze-thaw condition and slip criteria must be agreed before the crew enters. This guide covers substrate judgement, interface checks, work windows, grit sequence, drainage, acceptance and disputes for the contractor PM and owner representative.
Scope covers freezer rooms, chilled storage, the loading dock apron, cold-room corridors and transition strips to resin or tile. Before mobilization the PM confirms slab age, insulation, vapor barrier, joints and moisture readings; failing zones go into tender assumptions, not a site argument later.
Cold room slabs are poured monolithically with the structure, so the wearing floor is part of the substrate, not an added layer. After laitance and weak paste are removed and pores sealed by densifier, no film remains to embrittle under cycling. Freezer rooms are honed for abrasion, corridors target slip, the dock apron takes wheel wear first. A CSP 5–6 grade suits storage; organic coatings are ruled out because they turn brittle in cold air.
Before entry the PM records each zone: slab age, trowel finish, coatings, patches, cracks, joints and repair mortar. Soft powdery areas are logged for repair before the diamond sequence; a slab at CSP 1–2 after a light metal pass needs exposed-aggregate finish first. The slab cures 28–90 days before polishing; moisture is probed at depth, with RH and damp logged by zone. Probe RH stays below 75% before densifier; joints over 3–4 mm are photographed and measured.
Below the wearing slab sit rigid insulation and a vapor barrier; the screed-to-insulation interface controls whether the finish stays bonded. Hollow sounds under tapping, edge lifting and reflection cracks over insulation joints are flagged early. Chiller air holds 2–8 ℃ while freezers drop to -18 to -25 ℃; a weak interface opens first at joints and corners. Freeze-thaw damage appears as spalling, pop-outs and scaling; repair mortar cures 7–14 days before grinding.
Work runs in blocks, not one open floor. Divide into zones of 150–300 m² per cluster, each with entry, extraction run and protection; rooms, corridors and dock apron are separate zones by target. The daily block runs 3–4 hours of grinding or resin work, then cleanup; densifier areas stay closed overnight. Wheel traffic returns after 24–72 hours, equipment after the full sequence, normally 5–7 days from first pass. Polish ahead of commissioning, utilities and defrost still out of service.
Run the sequence metal to resin in full-floor passes. Metal starts at 16 or 20 grit to open laitance and find soft spots, then 30 and 40 grit; skip a grit only after a straightedge clears marks. Resin follows 100, 200, 400, 800, then 1500 or 3000; scratches carried to 800 cannot be hidden by 1500. Lanes overlap 100–150 mm; check each grit under 300–500 lux raking light. Densifier goes on dust-free: 1:64, about 15 ml/L, first coat; 1:128, about 8 ml/L, second, damp 20–40 minutes.
Acceptance is agreed in writing before work starts, with limits tied to measurable checks rather than the word "smooth". The table lists zone targets; each record carries zone, date, reading and sign-off, and the written criterion decides where readings differ.
| Zone | Finish target | Slip criterion | Inspection record |
|---|---|---|---|
| Freezer room | 400–800 grit, honed, sealed | Dry PTV ≥36; DCOF ≥0.42 | Per 200 m²; joint fill checked |
| Chiller corridor | 800–1500 grit, sealed | Wet PTV 10–20 below dry | PTV dry and wet logged |
| Dock apron | 1500–3000 set | R10–R12 wet approach | Photo of flagged area |
| Defrost zone | 400–800 grit, sealed | DCOF ≥0.42 under water | Drainage slope checked |
| Edge and threshold | Hand-ground match | Checked with strip | Edge signed off |
Defrost systems release water and condensate 2–4 times per day; the floor must shed it to channels. Check drainage slope at 1–2% toward drains or channels; drains, joints and cove corners are inspected first. Standing water after defrost is a drainage or joint problem, not a polish defect; correct slope or seal before slip testing. Keep RH 75–80% and surface temperature 10–30 ℃ during application, then ventilate. Storage rooms refresh on a 3–5 year cycle; dock apron and high-wheel zones checked every 2–3 years.
Walk the final inspection with the owner representative against the tender schedule, marking defects by number before any rework. Common disputes are uneven reflection, white haze after densifier, wet-zone slip resistance, and scratches after wheels return.
At handover supply the finish schedule, grit sequence, product names and dilution rates, joint treatment, reading records and a maintenance note. Walk the floor with the representative and show where inspection points sit. Confirm every zone has a signed record; open items carry a date and owner. The wear layer compacts in the first 6–12 months; dull patches near the dock are normal wear.
Written and reviewed by JOY TECH - an SGS & BV audited, CE/RoHS certified diamond tools manufacturer founded in 2004, exporting to 50+ countries.
Our factory and quality management system are audited by SGS and Bureau Veritas. Products meet CE/RoHS requirements and every piece is 100% inspected before packing.
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