The Tufco Process
See how our proven turnkey approach ensures quality control and reliable project execution at every stage.
Our Pledge to You
Because we custom-manufacture, deliver, and install every floor ourselves, we can guarantee all aspects of your floor, from the materials to the installation.
Assessment
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 installation crews.
Removal
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.
Prep
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.
Cleaning
Before we install the floor, the concrete is cleaned to remove any debris or dust that may have settled during the mechanical prep. If needed, or when a wet preparation method is used, the concrete is pressure-washed and dry-torched. This removes any debris or dust that may have settled during the mechanical prep and then removes moisture from the concrete as well. This way, our floor bonds directly to the substrate.
Formulation
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.
Application
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 off 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.
Completion
The final layer usually takes anywhere from 6 to 12 hours to be ready for production use. Our foreman walks the project with you, making sure you are happy with the finished floor.