Abrasives are the most important tool for mechanically processing concrete to a polished finish. They come in many forms, shapes and sizes and are made out of various materials whose bonding varies in hardness.
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There are multiple variables and conditions that need to be considered when choosing your abrasives, including physical make up and the conditions they will be used under. The manufacturer of the abrasive should be able to give you guidelines on how their abrasives best work under certain conditions.
Always keep in mind the material you are abrading (concrete and aggregate, glues, mastics, coatings) has to work together with your abrasive. Not using abrasives properly will affect both their performance and life. Here are five additional factors to consider when choosing the right abrasive:
Weight. The weight over the abrasives will affect how they function. Too little weight and the abrasive will not cut efficiently or properly; too much weight may cause excessive wear. Too much weight over resin bond abrasives may also cause resin transfer resulting in a floor whose polished appearance may not be the result of the mechanical process but the result of creating a layer of shiny resin.
RPM. The RPM of the machine has to be properly managed. Lower grits work better at lower speeds. A lower grit run at higher speeds will not properly bite and abrade the surface but instead glide or skip over the surface. One of the ways to run higher speeds is by adding more weight, but you will need a machine and an abrasive that is designed to run under heavier weight and higher speeds. Higher grits can be run at higher speeds because they are removing less material from the surface and do not need excessive bite with the surface. Running an abrasive not designed for higher speed will lead to resin transfer.
Rotation. If using a planetary head machine the directional rotation of the main head and satellite heads will affect how an abrasive cuts. When using a planetary head machine the main head rotates in one direction. The path of least resistance is for the satellite head to rotate in the opposite direction. If both the main head and satellite heads can be set to rotate in the same direction a more aggressive abrasion will occur.
Tread. The tread or face of an abrasive comes in several different styles. You can have two different types of abrasives both being 100 grit. One 100 grit abrasive may have twice as much surface contact than the other. Although they may both be 100 grit, the one with less surface contact will be more aggressive in how quickly it cuts and will also take longer to create a fully refined scratch pattern.
Speed. The speed at which equipment moves over the surface in a linear motion will dictate how well the abrasive abrades the surface. Moving the machine too fast will not allow the abrasive to create a consistent, tight scratch pattern. Moving too slowly with an abrasive typically below 50 grit may cut too quickly and remove more than intended.
Understanding abrasives will allow you to provide a better product in a more efficient manner and give you the know how to effectively work with all the various types of concrete you encounter in the field.
Editor's Note: This article has been updated from the original version, which first appeared in the January issue of Concrete Contractor.
Selecting the right abrasives for your metalworking applications can help you boost productivity, cut costs, and deliver higher quality results. But with the variety of abrasive products available, how do you know you&#;re choosing the ones best suited for you?
We&#;ve put together this guide to help you choose the appropriate abrasives and included information about the Walter Abrasive Selector app, a new tool from Walter that makes it easier than ever for you to find abrasives geared for your needs.
The four most popular kinds of abrasive wheels are:
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Other wheel types you might come across include emery (perfect for polishing) and garnet (the go-to choice for light-duty smoothing and hand-sanding jobs).
Some of the most popular shapes include:
The grit size is the number of individual abrasive grains present in the wheel. The lower the number (10, 16, 24, etc.), the coarser the grain. Coarser grains are ideal for more demanding tasks like fast cuts or heavy removal. Finer grains with higher counts (70, 100, 180, etc.) are suited for smaller, more detail-oriented jobs including subtle finishes and precise areas.
The bond or coating is what holds the abrasive grains together, helping them cut more effectively and gradually wearing away to expose newer, sharper grains. Vitrified bonds are strong, durable, and superior at standing up against harder use conditions and environmental factors. Organic bonds like rubber, resin, or shellac are capable of operating at higher speeds (6,500-9,500 surface feet per minute) and delivering more precise results.
The grade (given between A for soft and Z for hard) is what determines how tightly bonds hold the abrasives and can affect the wheel&#;s speed, grinding depth, feed rates, and more. The general rule of thumb is that softer grades are ideal for harder materials, while harder grades are better for softer materials.
Ultimately, finding the right wheel for your needs is about tying all of these factors together&#;the type of material you&#;ll be working with, how hard or soft it is, the amount of stock you need to remove, how fast you need to work, the horsepower of the machine you&#;re using, and other considerations.
When in doubt, contact the experts (whether the manufacturer or your supplier) for guidance.
Walter&#;s Abrasives Selector app helps metalworking professionals find the right product for their applications.
Click here to download the Walter Abrasives Selector app for Android!
Click here to download the Walter Abrasives Selector app for Apple!
Its user-friendly interface walks you through the process of picking the type of abrasive you need (cutting, grinding, blending, sanding, and finishing), the material you&#;re working with, and the tool you&#;re using. It also gives you on-the-go access to downloadable resources like data sheets, technical videos, and more.
Do you want to learn more about Walter&#;s innovative lineup of abrasive products? Contact Fastening House today!
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