Milling Pads Archives - Tile Doctor Lancashire

Black Limestone Floor Renovation in Lancaster

Clean and Seal of a Black Limestone Kitchen Floor in Lancaster

This customer from Lancaster contacted us about cleaning and sealing what they thought was a Blue Slate kitchen floor. Having spoke to them over the phone I arranged to pop over and survey the floor to get a better understanding of the work that needed to be done. Lancaster is a few miles South of our base in Carnforth and I’m always passing though.

Having visited the property I was able to confirm that the floor wasn’t Slate but Black Limestone which is notoriously high maintenance due to its acid sensitivity. I mentioned this and they were quite surprised as it had only been laid a few years earlier and it was sold as Black Slate. The two materials do look identical, but if you drop a small amount of something acidic on Black Limestone the stone fizzes and turns Grey and White.

Black Limestone Kitchen Floor Before Cleaning Lancaster

The big problem with Black Limestone is unlike Slate its very porous, this is why you see Slate being used for roof tiling and is still popular covering even to this day. Also, its very acid sensitive, so even Tea, Coffee, Juice, or Wine can mark it, so although popular in gardens it’s certainly not a stone we would recommend for use in a kitchen or bathroom.
Another problem you have is Black Limestone contains natural oils and it’s the oil that gives it that beautiful black colour. Once the oil is washed out of the stone over time or through the use of acidic cleaning products it leaves the stone looking grey and unattractive. This can be resolved however using an oil-based sealer but it is more expensive than a regular stone sealer.

Black Limestone Kitchen Floor Before Cleaning Lancaster

This stone is still workable though, so it’s not all bad news, with the right treatment it can look as good as the day it was laid (if not better) so I came up with a renovation plan that would do exactly that. They were happy to have the work done so we scheduled a date for the work to start.

Cleaning a Black Slate Floor Tiled Kitchen Floor

We find the best way to renovate floors like this is to use coarse diamond pads that can cut into the stone remove any surface damage, contaminates, old sealers and generally leave the stone very clean.

With this floor I started with a very coarse 50-grit DRB pad which is run several times over each stone using only water to lubricate the process. The process generates a lot of soiling and loose sediment that has to be rinsed off the floor with water and then extracted with a wet vacuum. Once this is done the process is repeated with a 100 and then 200-grit pad which together effectively re-hone the stone and remove any scratches caused by the previous pad. A dilution of Remove and Go was also used with the 200-grit pad to ensure the tiles were clean and any remaining sealer not caught by the pads had been removed.

The last step on the first day was to re-point the stone tiles where needed to remove failed and crumbling mortar. This was then left to set hard overnight so we could continue with the renovation the next day.

On day two we followed up the renovation of the stone by moving onto finer Burnishing pads starting with a 400-grit diamond pad applied in the same way and rinsing and extracting afterwards. This was followed by the application of an 800 and then 1500-grit pad to further refine and improve the stone.

Sealing a Black Slate Tiled Kitchen Floor

The following day the Black Limestone was sealed with a coat of Tile Doctor X-Tra seal which is the Oil based sealer I mentioned earlier. It brings out the true colour of this stone and the seal leaves a sheen appearance to give a very appealing finish. We find one coat is usually enough for this sealer as it’s a lot thicker that other sealers.

Black Limestone Kitchen Floor During Sealing Lancaster

Before leaving I talked through aftercare cleaning with two buckets and the importance of using a pH Neutral cleaning product. We recommend avoiding steam cleaners and not to use cheap bleach or acidic cleaning products which can damage the sealer with repeated use.

Black Limestone Kitchen Floor After Renovation Lancaster

We always encourage feedback from customers, and I’m pleased to be able to quote the following message they left on our feedback system:

Great service very organised and professional service would highly recommend

Black Limestone Kitchen Floor After Renovation Lancaster

Professional Restoration of a Black Limestone Kitchen Floor in Lancashire

Clean and Seal of a Black Limestone Kitchen Floor in Lancaster Read More »

Terrazzo Floor Renovation Beziers France

Renovating a Large Terrazzo Tiled Floor in Béziers France

The English owner of a French Chateau contacted Tile Doctor about the hard floors at their property in Béziers in the South of France. There were several floors at the property including Terrazzo, Limestone and Black and White Encaustic tiles all around a hundred years old and in a bad state of repair. There was a lot to cover so for this post we will focus on the Terrazzo flooring.

Terrazzo Floor Before Renovation Beziers France

We have been known to carry out tile renovation work in other counties so we were more than happy to consider a visit to the South of France and help bring the floors back to life. Previous overseas projects have included a hotel restaurant in Addis Ababa, holiday cottages in Ireland and a villa in France.

Luckily for us the customer had invested in some machinery that he had found on eBay but he didn’t have the technical knowledge to do the work and so had decided to seek help. Having discussed each of the floors in detail over the phone and with photographs sent via email I worked out a restoration plan for each floor.

We supplied the products he needed and we were flown down from Manchester to Béziers Cap d’Agde Airport where we were picked up by the client, (very Hollywood). If you have never been to Béziers before it’s well worth a visit, it’s a beautiful area, well laid out, with parks and rivers, an old 12th Century Monastery and the property had great views all around.

Tile Doctor Floor Renovation Bezier

Deep Cleaning and Filling Terrazzo Flooring in Béziers France

On arrival at the property work started with setting up the machinery and conducting some preliminary cleaning tests to work out the best approach. After that however our host insisted on showing us round Béziers, it was a Saturday afternoon and we were in the South of France so why not, they certainly know how to live properly down there.

Terrazzo Floor Before Renovation Beziers France

So, work started on the Sunday with the application of a 200-grit Milling pad and Oxy-Gel cleaning solution. I was concerned (due to some hairline cracks in the Terrazzo) that water would seep through into the rooms below (this was a big old townhouse set on four levels) so by using a gel-based product it would be easier to control and the moisture would be kept to a minimum.

Terrazzo Floor During Cleaning Oxy-Gel Beziers France

The resultant soiling was then extracted with a wet vacuum and attention moved to filling the cracks in the Terrazzo with a resin filler. Once the resin had cured the floor was cleaned again, this time with a 200-grit DRB Milling pad which contains diamond segments. The process was lubricated with water and progress was checked underneath several times to ensure the pad was working as expected.

Terrazzo Floor During Renovation Beziers France

Polishing a Terrazzo Floor in Béziers France

This work continued with increasingly finer diamond encrusted burnishing pads starting with a 400-grit Diamond burnishing pad and moving up to an 800-grit and finishing with a 1500-grit pad. Only water was used for lubrication and the soiling was extracted with a wet vacuum after each pad was applied. This method slowly improves the surface of the Terrazzo adding a long-lasting polished appearance.

The floor was left to dry overnight and the following day treated to a spray burnish using a very fine 3000 grit burnishing pad; the pad is applied dry to the floor with only a little amount of water which is sprayed onto the surface.

Sealing Terrazzo Flooring in Béziers France

This final 3000-grit pad leaves the floor dry and allows the floor to be sealed shortly afterwards. The sealer chosen for the Terrazzo was Tile Doctor Colour Grow which is a colour enhancing impregnator which works by soaking into the pores preventing dirt from residing there. Sealing the floors keeps the dirt and other contaminates on the surface where it can be easily removed.

Two coats of Colour Grow were applied and this brought out the lovely pink tones in the Terrazzo which together with the polished appearance really transformed the appearance of the floor.

Terrazzo Floor After Cleaning Beziers France

For aftercare cleaning I got the customer to purchase a five-litre bottle of Tile Doctor Neutral Cleaner along with the other products. You must be careful what you clean sealed floors with as many products contain bleach and are simply too strong resulting in the premature degradation of the sealer.

We spent the whole week at the property and as well as working on the other floors did find time to do some more sightseeing before flying back the following weekend.

Professional Renovation of a Terrazzo Flooring in France

Renovating a Large Terrazzo Tiled Floor in Béziers France Read More »

Black Caithness Slate After Renovation Gressingham

Caithness Black Slate Floor Restored with Milling Pads in Gressingham

1 Comment / Bentham Tile Cleaning, Lancaster Tile Cleaning, Slate Tile Cleaning / Russell Taylor

The photos above detail the restoration of Black Caithness Slate pavers at an old cottage in the village of Gressingham on the outskirts of Lancaster. The building was in the process of being completely overhauled and the floor was next on the long renovation to do list.

Black Caithness Slate Pavers Before Cleaning

Caithness Slate from the northern tip of Scotland and is known for its durability and strength however the years had certainly not been kind to this floor and it was in a very bad state.

To restore the appearance of the slate I recommended milling the floor with a set of very coarse pads that would remove a thin layer of stone off the top of the paving slab to reveal new stone underneath. The pointing was also cracked and loose in places so that would also need chopping out and replacing. After milling the stone would also be smoother and once sealed much easier to maintain going forward.

I estimated the process would take four days to complete. Happy to go ahead with the quote a date was booked for the work to start.

Resurfacing Caithness Black Slate

On the first two days there were two of us involved to get through milling the stone which is hard work. We used a set of milling pads applied to a weighted floor machine to cut through the stones surface using water for lubrication. This generates a lot of stone dust so a lot of rinsing and extracting needs to happen to remove it.

Milling carried on into day two but by the end we had started knocking out the old pointing which had already failed and wasn’t too difficult to remove. It was one big room with a partition at one end, the building itself was built in the 1870s or at least that’s as much information as the client could find as it was bought in an auction.

Black Caithness Slate Pavers During Renovation

Due to its age, it had no water or electricity, so we had to work off generators whilst a rudimentary system supplied the water. This was not the easiest job for us as the generators were proving difficult to work with as the relays would overload and cut off the power; this happened more than a dozen times just in the first day alone, but we like a challenge.

As you will see from the pictures the stone flagstones were transformed. This was not a simple clean and seal job, this is milling back the surface using various diamond grits a heavy weighted buffing machine and patience, and some water. Using a wet system, the milling system won’t leave a house full of dust and the diamond grinding leaves the stone much smoother and a lot cleaner which makes it a lot easier to clean and maintain in the future.

Sealing a Caithness Black Slate Tiled Floor

Once the milling was complete and the new flexible breathable pointing was applied for which we like to use a product called VDW 800. We then called back the next day and finished the clean, the floor area was left for another day to dry.

Black Caithness Slate Pavers During Sealing

Once dry, the floor was then sealing using a single coat of Tile Doctor X-Tra seal which is oil-based sealer that really brings out the colour of the Black slate. Additionally, this sealer is fully breathable so it will cope with the damp conditions you find with old floors that don’t have a damp proof membrane and so won’t peel off after a few weeks.

Black Caithness Slate Pavers After Renovation

The client was very happy with the transformation and final finish and invited us back to cover more work in the outbuildings which eventually will join onto the main house. For aftercare cleaning I recommended Tile Doctor Neutral Clean which is an effective tile and grout cleaner that won’t upset the sealer.

Professional Restoration of a Caithness Black Slate Tiled Floor in Lancashire

Caithness Black Slate Floor Restored with Milling Pads in Gressingham Read More »

Flagstone Floor Restoration Lytham St Annes

Original Flagstone Tiled Floor Restoration in Lytham St Annes

1 Comment / Flagstone Tile Cleaning, Lytham St Annes Tile Cleaning, Sandstone Tile Cleaning / Russell Taylor

The client said when he moved into this house in Lytham St Annes late last year that this room had a really bad smell of damp. The Flagstone floor was covered in carpet and he had the impression that the previous owner’s cat had been known to use it as place to pee!

Flagstone Floor Before Restoration Lytham St Annes

The smell was rank and probably bad for your health so he decided to remove the carpet and the thick underlay underneath. Under that there was some old Vinyl flooring which all came out to reveal the original flagstone floor. As you can see from the pictures it was in a poor state covered in red and white paint, bits of bitumen here and there and the pointing had been lost in several areas of the floor. Additionally, all those layers over the stone would have prevented any moisture from naturally evaporating at the surface thereby resulting in damp.

The client had seen what we could do on our website and sent us some pictures of his floor which covered approximately 16m2. I priced for milling the flagstone as a deep clean would not resolve the shaling issues on its own and only a good mill of the stone would do that. Also, it needed all the pointing that was still in place knocking out and new flexible breathable pointing put back in place.

Cleaning and Repairing a Flagstone Tiled Hallway Floor

Milling stone is not a low-cost option, but it is a lot more cost effective than pulling up the whole floor and putting in a modern subfloor. Milling involves using a weighted buffing machine fitted with different grits and grades of coarse Diamond encrusted pads which cut into the surface of the stone to reveal new stone underneath, you then apply finer pads to hone and refine the surface.

In this case I used a set of Tile Doctor Milling Pads applied in sequence starting with 50-grit, 100-grit and then 200-grit. Water is used to lubricate the process and keep the dust down, it’s also important to rinse the stone off after each pad and extract the slurry that is generated with a wet vacuum.

The floor was then cleaned with Tile Doctor Remove and Go allowing the product to soak in for ten minutes to loosen deep seated paint staining. The Tile Doctor Remove and Go was then worked in with another 200-grit pad before another rinse and extract again with the wet vacuum.

Older floors like this were installed before the invention of the damp proof membrane so moisture is always a concern. To counter any issues that might develop later such as Efflorescence the last step in the cleaning process was to give the floor an acid rinse using Tile Doctor Grout Clean-up, this neutralises any latent salts trapped in the subfloor.

Sealing a Flagstone Tiled Hallway Floor

The milling, re-pointing and cleaning work took two days and we returned for a third day to apply a breathable sealer called Tile Doctor X-Tra Seal. This product is fully breathable and a great choice for any floors where damp can be a problem as it will allow for moisture to rise through the stone and evaporate at the surface. Being oil-based it also adds character to natural stone and adds an appealing low satin finish.

Flagstone Floor After Restoration Lytham St Annes

The whole process completely transformed the appearance of the flagstone floor and really suits the property which was a late Victorian four-story house with a basement. Original features like this are very sought after so it makes sense to restore them as it will add value.

An additional advantage of the milling process is it also reduces the roughness of the stone surface makes it smoother and easier to clean. On the topic of cleaning its worth mentioning that you should never use a strong bleach-based tile cleaning product on a sealed floor as it will erode the sealer prematurely. For a floor like this you need to use a product like Tile Doctor Neutral Cleaner which is a mild but effective cleaning product designed for use on sealed tile and stone.

Professional Restoration of a Flagstone Floor in Lancashire

Original Flagstone Tiled Floor Restoration in Lytham St Annes Read More »

Indian Sandstone Kitchen Floor Renovation Garstang

Rough Indian Sandstone Floor Milled and Restored in Garstang

1 Comment / Garstang Tile Cleaning, Grout Cleaning, Sandstone Tile Cleaning / Russell Taylor

Due to the textured nature of the Indian Sandstone tiles installed their kitchen, this client from Garstang was having trouble keeping their stone floor clean. Having decided enough was enough they contacted Tile Doctor to see what could be done to rectify the problem.

I went over to survey the floor and could see dirt was being trapped in the riven surface of the Sandstone and any sealer put there to protect the stone had long since worn off. I find the best solution for rough stone floors like these is to mill the stone with coarse diamond pads thereby removing the grubby surface layer and revealing a new surface underneath. This action also flattens the stone to remove the roughness and makes it easier to maintain.

Indian Sandstone Kitchen Floor Before Cleaning Garstang

I provided a price for milling the stone, cleaning up the grout lines and then applying a new sealer to protect it going forward. Happy with the price, the client arranged to purchase the required products, and we booked in a date for the work to commence. It was only a small 5 m2 area so I was happy that it could be done by one Tile Doctor over a couple of days.

Cleaning and Restoring an Indian Sandstone Tiled Kitchen Floor

To mill the Sandstone, we use a couple of very coarse milling pads of different grades which are applied to the stone with water for lubrication. The pads are fitted to a rotary floor machine to which extra weight is added to ensure a good contact with the stone. The floor was rinsed with water as I progressed, and the soiling generated was extracted with a wet vacuum.

Indian Sandstone Kitchen Floor During Cleaning Garstang

Circular pads do struggle to maintain contact with the edges and especially corners so this is done manually using a set of hand-held diamond blocks. I also scrubbed the grout lines with Tile Doctor Pro-Clean to get the lines as clean as possible.

It’s worth noting that Indian Sandstone is full of iron and a lot harder to mill compared to English Sandstone, Flagstone, and Slate etc. As a result, it took most of the first day to complete this stage.

Sealing an Indian Sandstone Tiled Kitchen Floor

Once milled and cleaned I left the sandstone to dry off overnight and then called back the next day to apply the sealer. For this floor we went with Tile Doctor X-Tra Seal which is a breathable oil-based sealer that contains a colour enhancing formula to improve the general appearance of the stone.

Indian Sandstone Kitchen Floor After Cleaning Garstang

What might not be noticeable from the pictures is the smoothness of the stone after it’s been milled, this makes it a lot easier to clean and makes it a lot less absorbent to dirt and muck etc.

The fresh sealer will maintain its appearance for many many years to come and maybe in another 100 years it will need to be milled again.

It always helps to use the right product when cleaning stone after it’s been sealed, so we dropped off a bottle of pH Neutral Cleaner for the client which we call Tile Doctor Neutral Tile Cleaner. This will ensure easy maintenance without damaging the sealer.

Professional Restoration of an Indian Sandstone Tiled Kitchen in Lancashire

Rough Indian Sandstone Floor Milled and Restored in Garstang Read More »

Sandstone Flagstone Floor Restoration Preston

Flaking Sandstone Flagstone Floor Restored in Preston

1 Comment / Flagstone Tile Cleaning, Preston Tile Cleaning, Work by Category, Work by Location, Work History / Russell Taylor

The pictures below are of a 12m2 Sandstone Flagged floor at a property in Prestonwere the surface of the stone was flaking off. The floor looked terrible and more importantly my customer mentioned that visitors had occasionally tripped on the uneven stone, and this was causing some concern.

Flagstone Floor Preston Before Renovation

The most likely cause of the surface flaking or shaling was due to water damage at some point in the stone’s history and probably well before the flagstones were laid. However here at Tile Doctor we have developed a solution for this problem called Milling. The process involves applying very abrasive floor pads to the stone in order cut back approximately 3 to 5mm of damaged stone from the top of the slab to reveal a fresh surface underneath. Essentially it will reface the stone and, in the process remove heavy lippage to leave a smoother beautiful surface that is easier to clean and maintain.

Another job which we agreed to do was to knock out the old pointing (what there was of it) and apply fresh. With the Sandstone flagstones smoothed, new pointing and stone sealed the floor was going to be transformed and unrecognisable once completed.

Milling a Flaking Sandstone Flagged Floor

Milling Sandstone flagstones involves the use of a set of thee coarse millings pads of different grades (50, 100 and 200 grit). They are applied to the stone in sequence beginning with the 50-grit pad and applied using a weighted heavy duty floor buffer. This generates a lot of dust, so water is used to lubricate and keep the dust down. During the process the water turns into a murky brown slurry which needs to be rinsed off and extracted using a wet vacuum as you go.

With the shaling removed it was then a question of polishing up the surface of the stone with the finer 100 and then 200-grit milling pads. Again, water is used to lubricate and capture the dust created during the process and then rinsed away and extracted with the wet vacuum.

Flagstone Floor Preston During Renovation

The process successfully managed to remove all the flaking material, flatten out the lippage and remove the unappealing surface.

When it comes to repointing old flagstone floors, I find a lot of builders and tilers I speak to usually recommend Limecrete or similar which is staple for old floors as its breathable, but I find it difficult to work with and it takes a long time to cure fully. Another problem is every time the floor is given a decent clean, some of the White Limecrete rinses out and into the stone.

Personally, I like to use a German product called VDW800, its fully breathable, has a reliable working time, its easy to apply and does a great job. I’ll put a link to a video about it in this post so you can see how to use it. It’s not a Tile Doctor product but I’m more than happy to endorse it.

Sealing Flagstone Floor Tiles

The stone and fresh mortar was left to dry out for 48 hours to ensure it would be dry before completing the last stage of applying a sealer. Before starting with sealing, I gave the floor light clean to remove any loose mortar from the pointing.

One done I sealed the sandstone using several coats of Tile Doctor Colour Grow, which is an impregnating product that soaks into the pores of the stone and occupies that space preventing dirt from become ingrained. Colour Grow as its name suggests also improves the appearance of the stone by enhancing its natural colours. The sealer also leaves a matt finish, which is a perfect match for the rustic character of the old stone.

Flagstone Floor Preston After Renovation

For aftercare I recommend using a pH neutral tile cleaner such as Tile Doctor Neutral Tile Cleaner, many supermarket products are very strong and contain bleach, using something like that on a sealed floor will reduce the life of the sealer.

Professional Transformation of a Flaking and Uneven Stone Floor in Lancashire

Flaking Sandstone Flagstone Floor Restored in Preston Read More »

Flagstone Floor Before and After Milling Haslingden

Milling and Sealing Uneven Flagstone Flooring in Haslingden

1 Comment / Flagstone Tile Cleaning, Preston Tile Cleaning, Work History / Russell Taylor

Flagstones are a durable Sandstone based material that give a solid feel to any floor, however while large and impressive to look at they can be very rough and un-even. This isn’t so much of a problem when Flagstones are used externally for patios and pathways, but rough surfaces trap dirt and when these tiles are used internally, they are much easier to maintain if the stone is smooth and sealed.

This customer, who lives in the Lancashire town of Haslingden, had this problem with their Flagstone tiled floor and like most things related to tile, stone and grout we have a solution in the form of a process known as milling. This basically involves grinding down the surface of the tile using coarse diamond encrusted pads to make it smooth.

Flagstone Floor Before Milling Haslingdon

The customer booked me in to get the job done, having seen some previous milling work of ours on our website and liking what we had achieved for other people with similar floors.

Milling an Uneven Flagstone Tiled Floor

Milling the stone involves the use of a set of thee millings pads of different grades (50, 100 and 200 grit) which are applied in sequence. You start with the coarse and abrasive 50 grit milling pad and follow this by smoothing this surface with the finer 100 and 200 diamond grit milling pads. Water is used to lubricate and capture the dust which is created during the process resulting in a slurry which needs to be rinsed away and extracted between each pad. The process requires the use of a solid weighted rotary machine and a fair bit of muscle power to guide it.

We successfully managed to mill the Flagstone tiles virtually flat in places and the process removed the unappealing stained and dirty layer of stone that was ruining the appearance of the floor. Interestingly we usually find that by grinding away the old and dirty layer of stone the true colour of the tiles that had been hidden under many years’ worth of muck is revealed. Unfortunately, in this case, due to the darkness of this stone it was difficult to see a great deal of colour change.

Sealing Flagstone Floor Tiles

Finally, the floor needed to be sealed to protect against future instances of staining and ingrained dirt. To do this I sealed the tiles using several coats of Tile Doctor Colour Grow, which is an impregnating, colour enhancing sealer that soaks into the pores of the stone and occupies that space preventing dirt from become ingrained. The sealer also leaves a matte, natural looking finish, which is a perfect match for the rustic character of the Flagstone tiles.

Flagstone Floor After Milling Haslingdon

Now that the floor has been levelled and sealed, the surface is smooth and protected. This means the customer will not be ruining any more mops when the cleaning bucket comes out!

Professional Milling and Sealing of Stained and Uneven Floor in Lancashire

Milling and Sealing Uneven Flagstone Flooring in Haslingden Read More »