Crappy powerfloat - any solution?

[Nibbler]

Hi, I hope someone can help...I have just had a concrete base laid, about 14 feet by 30 feet. It was meant to be powerfloated, as I need a very smooth, scrubbable, disinfectable surface (it's for keeping animals). I've seen powerfloated surfaces that were done well, and they are like smooth marble. This is nothing like what I got: although some is quite smooth, other places are missing the smooth crust, there are areas of a few inches across that are totally rough, about 1-2 mm deep, and some worse patches especially around the edges. I don't think there is a single square metre in the whole thing that is really perfect.

My two questions are: (1) were my expectations too high? The builder claims that is as good a surface as I could have hoped for. and (2) What is the best way to get this surface smooth and shiny, without ripping the whole thing up and starting over? Is there a screed that can be applied that will do the same thing? I have looked at industrial flooring epoxies, etc, and that would cost more than a new slab. (I am in the UK). Thanks for any advice.

[Rich]

Your expectations are not too high. Our crew has done 10000sf floors with a flatness of 1/16" in 10' (standard is 1/4") and not a ripple in the whole thing all in one day.
After they powerfloated it did they steel trowel it? They should've gotten skids on and steel troweled the whole thing for the final finish. This is where the durable, smooth finish comes from. The powerfloat only gets the flatness close so the trowels can get the final finish.
I would go back to the contractor and make him fix it if it's not to the quality specified. Your other option is to get some Tamspatch (or other concrete patch) and fill in the really bad area and then get a floor grinder to get rid of the rough spots.

[roger g]

Ive seen where they pour an epoxy allover the floor and it shines just like marble. I don't know what size of imperfections the epoxy can cover though.

Roger

[Nibbler]

Thanks for your advice. I have had someone come to look at it, and they reckon the slab can be salvaged. i was advised to fill the bigger holes with ceramic tile adhesive. I have also found a product called reno-seal which is a coating that also penetrates the concrete. That should give a smooth finish, but also claims to protect the concrete especially against cracks. Is this something that anyone has used? It seems quite cost-effective, about £200 for 75 sq metres.