The Tufco Installation Process
Our company began in the late ’50s when the Cox brothers realized a need for a long-lasting concrete resurfacing process. After much research, they developed a non-porous, resin-based system that was highly successful. This eventually evolved into the system that Tufco installs today.
The first step naturally is planning. Our Sales Representatives determine the current problems, the ideal solutions, and what that scope of work means for both our clients and our installations crews.
If an existing floor is failing, our crews will remove it. With tile, brick, or another resinous floor, we typically use jackhammers for the removal process. For VCT Tile or linoleum, specialized scrapers provide a quick method of removal.
The concrete substrate is mechanically prepped with floor grinders. We use jackhammers to “key” along the edges of drains, doorways, cracks in the concrete, and expansion joints, making the floor about 1” thick in all these areas. This helps prevent cracks from continuing up through the floor, and to seal better against moisture.
Before we install the floor, the concrete is then pressure-washed and dry-torched. This removes any debris or dust that may have settled during the mechanical prep, and then to remove moisture from the concrete as well. This way, our floor bonds directly to the substrate.
Our resins are mixed on-site from 55-gallon drums and then applied directly to the concrete substrate. Tufco materials are proprietary blends, formulated to provide excellent adhesion, chemical resistance, and exceptional durability.
The resin mixture is spread thin across the prepped concrete with the use of squeegees. We then broadcast aggregate into the mixture. After the layer has cured, we sweep of excess aggregate. Depending on the flooring system, we may install three to five layers, with different resins and aggregates. This allows us to create custom solutions, as well as a “resin-rich” system, as opposed to troweled-on systems. By broadcasting aggregate into thin layers and building up the thickness, we use more resin and less aggregate. This leads to a longer-lasting floor.
The final layer usually takes anywhere from 6-12 hours to be ready for production use. Our foreman walk the project with you, making sure you are happy with the finished floor.